Heat exchanger and method of manufacturing heat exchanger

ABSTRACT

Mg and Bi are contained in each of a first fillet in a first braze joining portion in which a tube and a fin join, a second fillet in a second braze joining portion in which the tube and a header plate join, and a third fillet in a third braze joining portion in which the header plate and a tank body join. A concentration of Mg of each of the first to third fillets is from 0.2% or more to 2.0% or less by mass. When the tube includes a brazing material layer, a concentration of Mg of the tube at its plate thickness center is from 0.1% or more to 1.0% or less by mass. When the fin includes a brazing material layer, a concentration of Mg of the fin at its plate thickness center is from 0.2% or more to 1.0% or less by mass.

CROSS-REFERENCE TO RELATED APPLICATION

This patent application is based on and claims priority to JapanesePatent Application 2018-192060, filed on October 10,2018 in the JapanPatent Office, the entire disclosure of which is hereby incorporated byreference herein.

BACKGROUND Technical Field

Embodiments of this disclosure relate to a heat exchanger and a methodof manufacturing the heat exchanger.

Related Art

A technology of brazing an aluminum member in an inert gas atmospherewithout using flux is known. With the known technology, the aluminummember is brazed in a lower oxygen concentration environment than theatmosphere at atmospheric pressure without using flux or vacuum. Toeffectively join a hollow structure and a cylindrical member together, aknown technology specifies material of each of components of the hollowstructure.

However, since an aluminum alloy heat exchanger is configured bymultiple components respectively having different plate thicknesses fromthe other, the heat exchanger necessarily includes a relatively thinnerplate having a given thickness and a thicker plate thicker than thethinner plate. Hence, the heat exchanger includes three types of brazejoining portions including a braze joining portion in which thin platesjoin, a braze joining portion in which the thin and thick plates joinand a braze joining portion in which the thick plates join. Accordingly,when performing flux-less brazing to produce the heat exchanger made ofaluminum in the inert gas atmosphere, three types of braze joiningportions need to be satisfactorily formed.

However, the known technology does not specify conditions of forming thethree types of braze joining portions, and simply discusses material ofone of the members of the heat exchanger. Hence, even if one of thethree types of braze joining portions is preferably formed, remainingbraze joining portions cannot preferably be formed. That is, all of thethree types of braze joining portions are not preferably formed at thesame time. Further, in the flux-less brazing, a braze-joining processcan be performed at a higher pressure than atmospheric pressure.

In this point of view, it is an object of the present disclosure toprovide a heat exchanger made of aluminum with joining portions properlybrazed in a lower oxygen concentration than the atmosphere at eitheratmospheric pressure or a pressure higher than atmospheric pressure. Itis also an object of the present disclosure to provide a method ofmanufacturing such a heat exchanger.

SUMMARY

Accordingly, one aspect of the present disclosure provides a novelaluminum alloy heat exchanger produced by excluding flux capableresolving a conventional problem as discussed in Japanese unexaminedPatent Application Publication No. 2016-215248 (JPA-2016-215248-A). Thatis, the novel aluminum alloy heat exchanger includes: a flow channelforming member to form a flow channel in which a fluid flows through;and a heat transfer member having a heat transfer surface. The heattransfer member is joined to a flow channel forming surface of the flowchannel forming member. The heat transfer surface is wider than the flowchannel forming surface. The novel aluminum alloy heat exchanger alsoincludes: a tank member joined to the flow channel forming member toform a tank space communicating with the flow channel of the flowchannel forming member; a joining member joined to the tank member; anda first fillet formed in a first braze joining portion, in which theheat transfer member and the flow channel forming member join with eachother. The novel aluminum alloy heat exchanger also includes, a secondfillet formed in a second braze joining portion in which the flowchannel forming member and the tank member join with each other; and athird fillet formed in a third braze joining portion in which the tankmember and the joining member join with each other. The flow channelforming member, the heat transfer member, the tank member and thejoining member are composed of aluminum alloys, respectively. An averageplate thickness of the flow channel forming member is from 0.100 mm ormore to 0.400 mm or less, an average plate thickness of the heattransfer member is from 0.025 mm or more to 0.150 mm or less, an averageplate thickness of the tank member is from 0.500 mm or more to 2.000 mmor less, and an average plate thickness of the joining member is from0.500 mm or more to 2.000 mm or less. Each of the first to third filletsis composed of an aluminum alloy contains magnesium, bismuth andsilicon. A concentration of the magnesium of each of the fillets rangingfrom 0.2% or more to 2.0% or less by mass. At least one of the flowchannel forming member and the heat transfer member includes a brazingmaterial layer on a surface thereof. When the flow channel formingmember includes the brazing material layer, a concentration of themagnesium of the flow channel forming member at its plate thicknesscenter is from 0.1% or more to 1. (1% or less by mass. When the heattransfer member includes the brazing material layer, a concentration ofthe magnesium of the heat transfer member at its plate thickness centeris from 0.2% or more to 1.0% or less by mass.

In another aspect of the present disclosure, a novel aluminum alloy heatexchanger produced by excluding flux includes: a flow channel formingmember to form a flow channel in which a fluid flows through; and a heattransfer member having a heat transfer surface. The heat transfer memberis joined to a flow channel forming surface of the flow channel formingmember. The heat transfer surface is wider than the flow channel formingsurface. The novel aluminum alloy heat exchanger excluding flux furtherincludes, a reinforcing member joined to the flow channel forming memberto reinforce the flow channel forming member; a joining member joined tothe reinforcing member; and a first fillet formed in a first brazejoining portion in which the heat transfer member and the flow channelforming member join with each other. The novel aluminum alloy heatexchanger excluding flax further includes: a second fillet formed in asecond braze joining portion in which the flow channel forming memberand the tank member join with each other; and a third fillet formed in athird braze joining portion in which the reinforcing member and thejoining member join with each other. The flow channel forming member,the heat transfer member, the reinforcing member and the joining memberare composed of aluminum alloys, respectively. An average platethickness of the flow channel forming member is from 0.200 mm or more to0.600 mm or less. An average plate thickness of the heat transfer memberis from 0.025 mm or more to 0.150 mm or less. An average plate thicknessof the reinforcing member is from 0.600 mm or more to 2.000 mm or less.An average plate thickness of the joining member is from 0.600 mm ormore to 2.000 mm or less. Each of the first to third fillets is composedof an aluminum alloy containing magnesium, bismuth and silicon. Aconcentration of the magnesium of each of the first to third fillets isfrom 0.2% or more to 2.0% or less by mass. At least one of the flowchannel forming member and the heat transfer member includes a brazingmaterial layer on a surface thereof. When the flow channel formingmember includes the brazing material layer, a concentration of themagnesium of the flow channel forming member at its plate thicknesscenter is from 0.1% or more to 1.0% or less by mass. When the heattransfer member includes the brazing material layer, a concentration ofthe magnesium of the heat transfer member at its plate thickness centeris from 0.2% or more to 1.0% or less by mass.

In yet another aspect of the present disclosure, a method ofmanufacturing the heat exchanger includes the steps of: assemblingcomponents into the heat exchanger; placing an assembly of the heatexchanger in an oxygen concentration ambience lower than the atmosphereat either atmospheric pressure or a pressure higher than atmosphericpressure; and brazing components of the heat exchanger without coatingflux thereon.

That is, according to one embodiment of the present disclosure, as eachof components of the heat exchanger before brazing, each of componentsconfigured to meet the above-described conditions after brazing is used.Subsequently, in the environment of lower oxygen concentration than theatmosphere at either atmospheric pressure or a pressure higher thanatmospheric pressure, the heat exchanger is brazed without using flux.With this, three types of braze joining portions including the brazejoining portion in which two thin plates join, the braze joining portionin which the thin and thick plates join and the braze joining portion inwhich two thick plates join can be satisfactory formed. Specifically,the heat exchanger can be satisfactorily brazed at the joining portions.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the present disclosure and many of theattendant advantages of the present disclosure will be more readilyobtained as substantially the same becomes better understood byreference to the following detailed description when considered inconnection with the accompanying drawings, wherein:

FIG. 1 is a cross-sectional view illustrating a heat exchanger accordingto a first embodiment of the present disclosure;

FIG. 2 is a cross-sectional view illustrating a tube and a finillustrated in FIG. 1;

FIGS. 3A to 3F are enlarged views illustrating typical examples of asection III illustrated in FIG. 2, respectively;

FIG. 4 is a cross-sectional view illustrating a header plate and thetube illustrated in FIG. 1;

FIGS. 5A to 5K are enlarged views illustrating typical examples of asection V illustrated in FIG. 4, respectively;

FIG. 6 is a cross-sectional view taken along a line VI-VI illustrated inFIG. 1;

FIGS. 7A to 7L are enlarged views illustrating typical examples of asection VII illustrated in FIG. 6, respectively;

FIG. 8 is a cross-sectional view illustrating a separator illustrated inFIG. 1;

FIGS. 9A to 9F are enlarged view's illustrating typical examples of asection IX illustrated in FIG. 8;

FIG. 10 is a cross-sectional view illustrating a side plate and theheader plate illustrated in FIG. 1;

FIGS. 11A to 11G are enlarged views illustrating typical examples of asection XI illustrated in FIG. 10, respectively;

FIG. 12 is a cross-sectional view illustrating typical tubes before andafter brazing according to one embodiment of the present disclosure;

FIG. 13 is a cross-sectional view illustrating other typical tubesbefore and after brazing according to one embodiment of the presentdisclosure;

FIG. 14 is a cross-sectional view illustrating a tube and a header plateto explain a method of measuring an average plate thickness and a Mgconcentration at a plate thickness center according to one embodiment ofthe present disclosure;

FIG. 15 is a cross-sectional view illustrating a tube and a fin toexplain a method of measuring an Mg concentration of a fillet accordingto one embodiment of the present disclosure;

FIG. 16 is a cross-sectional view illustrating a tube and a header plateto explain a method of measuring an Mg concentration of the filletaccording to one embodiment of the present disclosure;

FIG. 17 is a graph illustrating a result of a line analysis of an Mgconcentration of a fillet executed by using an EPMA according to oneembodiment of the present disclosure;

FIG. 18 is a graph illustrating a result of a line analysis of an Mgconcentration of a tube executed by using the EPMA according to oneembodiment of the present disclosure;

FIG. 19A is a cross-sectional view illustrating a tube according to asecond embodiment of the present disclosure;

FIG. 19B is a graph illustrating a result of a line analysis of a Mgconcentration of the tube executed by using the EPMA according to thesecond embodiment of the present disclosure;

FIG. 20 is a cross-sectional view illustrating a tube according to athird embodiment of the present disclosure;

FIG. 21 is a cross-sectional view illustrating a tube and a finaccording to fourth and tenth embodiments of the present disclosure;

FIGS. 22A to 22D are cross-sectional views illustrating typical examplesof a tube and a fin according to a seventh embodiment of the presentdisclosure, respectively;

FIG. 23 is a graph illustrating a relation between a distance from asurface of the tube and a potential according to the seventh embodimentof the present disclosure;

FIG. 24 is a cross-sectional view illustrating a heat exchangeraccording to an eighth embodiment of the present disclosure;

FIG. 25 is a cross-sectional view illustrating typical first and secondplates and a first fin according to an eighth embodiment of the presentdisclosure;

FIGS. 26A to 26E are enlarged views illustrating typical examples of asection XXVI illustrated FIG. 25, respectively;

FIG. 27 is an enlarged view illustrating an example of a section XXVIIillustrated FIG. 24;

FIGS. 28A to 28J are enlarged views illustrating typical examples of asection XXVIII illustrated in FIG. 27, respectively;

FIG. 29 is an enlarged view illustrating an example of a section XXIXillustrated FIG. 24;

FIGS. 30A to 30L are enlarged views illustrating typical examples of asection XXX illustrated in FIG. 27, respectively;

FIG. 31 is a cross-sectional view illustrating a heat exchangeraccording to a ninth embodiment of the present disclosure;

FIG. 32 is an enlarged view illustrating a section XXXII illustratedFIG. 31;

FIG. 33 is an enlarged view illustrating a section XXXIII illustratedFIG. 31;

FIG. 34 is cross-sectional view illustrating a tube and a fin accordingto a tenth embodiment of the present disclosure;

FIG. 35 is a cross-sectional view illustrating a heat exchangeraccording to another embodiment of the present disclosure;

FIG. 36 is a cross-sectional view illustrating a heat exchangeraccording to yet another embodiment of the present disclosure; and

FIG. 37 is a cross-sectional view illustrating a heat exchangeraccording to yet another embodiment of the present disclosure.

DETAILED DESCRIPTION

Referring now to the drawings, wherein like reference numerals designateidentical or corresponding parts throughout the several view s thereof,and to FIG. 1, a first embodiment of the present disclosure isdescribed. As shown in FIG. 1, a heat exchanger 10 is a fin-tube typeheat exchanger in this embodiment. The heat exchanger 10 includesmultiple tubes 12 and multiple fins 14, two header tanks 16 and two sideplates 18. In FIG. 1, how ever, only one of the two header tanks 16 isillustrated. Also, only one of the two side plates 18 is illustrated.The heat exchanger 10 exchanges heats of a first fluid flown in themultiple tubes 12 and a second fluid flown outside of the multiple tubes12.

The tube 12 is a tubular flow channel forming member to form a flowchannel for the first fluid. The tube 12 is prepared by molding analuminum alloy plate into a hollow structure. The tube 12 is also a seamwelded pipe prepared by machining a sheet metal. However, the tube 12can be an extruded perforated pipe. The multiple tubes 12 are disposedin one direction at a given interval.

In this embodiment, the fin 14 is composed of an outer fin type placedoutside of the tube 12. The fin 14 is a heat transfer member having awider heat transfer surface than an outer surface of the tube 12. Thefin 14 promotes heat transfer between the primary fluid in the tube 12and the second fluid outside the tube 12. The fin 14 is a corrugate fintype prepared by molding an aluminum alloy plate into a corrugatedstate. However, the fin 14 can be molded into a different shape than thecorrugated state.

Each of the multiple fins 14 is positioned between adjacent tubes 12among the multiple tubes 12. However, a part 14 a of the multiple fins14 is placed between the side plate 18 and the tube 12.

As shown in FIG. 2, the fin 14 is brazed to an outside of the tube 12.In a braze joining portion 20, in which the tube 12 and the fin 14 join,a fillet 22 is formed. In the claimed invention, the fillet 22corresponds to a first fillet in the braze joining portion formed theheat transfer member and the flow channel forming member. Specifically,the braze joining portion 20 includes a first brazing material portionsandwiched between these members 12 and 14 joined together and thefillet 22 acting as a second brazing material portion spreading from thefirst brazing material portion.

As illustrated FIGS. 3A to 3F, each of the tube 12 and the fin 14 canemploy various layer structures and can be combined with each other invarious manners, wherein a fillet 22 is intentionally omitted for thepurpose of simplicity. As shown in FIGS. 3A to 3F, a brazing materiallayer 122 is provided on at least one of surfaces of the tube 12 and thefin 14.

In an example of FIG. 3A, the tube 12 includes a core material layer 121and a brazing material layer 122. The brazing material layer 122 islocated on an outside of the tube 12 facing the fin 14. The fin 14 mayconsist only of a core material layer 141. In an example of FIG. 3B, thetube 12 includes a core material laser 121 and two brazing materiallayers 122 and 123. More specifically, the brazing material layer 123 islocated inside of the tube 12. The fin 14 may consist only of a corematerial layer 141 as well.

In an example of FIG. 3C a tube 12 may consist only of a core materiallayer 121. A fin 14 includes a core material layer 141 and two brazingmaterial layers 142 and 143. The two brazing material layers 142 and 143are located on both sides of the core material layer 141, respectively.In the example of FIG. 3C, the tube 12 is either a seam welded pipe oran extruded perforated pipe. In an example of FIG. 3D, a tube 12includes a core material layer 121 and a brazing material layer 123. Afin 14 includes a core material layer 141 and two brazing materiallayers 142 and 143.

In an example of FIG. 3E, a tube 12 includes a core material layer 121and a brazing material layer 122. A fin 14 includes a core materiallayer 141 and two brazing material layers 142 and 143. Further, in anexample of FIG. 3F, a tube 12 includes a core material layer 121 and twobrazing material layers 122 and 123. A fin 14 also includes a corematerial layer 141 and two brazing material layers 142 and 143. Hence,in each of the examples of FIGS. 3E and 3F, the brazing material layer142 of the tube 12 is joined to the brazing material layer 122 of thefin 14. Further, depending on a situation, the brazing material layer122 of the tube 12 is joined to the brazing material layer 143 of thefin 14.

Here, each of the core material layer 121 of the tube 12 and of the corematerial layer 141 of the fin 14 is composed of an Al—Mn-based alloy.Each of the brazing material layers 122 and 123 of the tube 12 iscomposed of an Al—Si-based alloy. Also, each of the brazing materiallayers 142 and 143 of the fin 14 is composed of an Al—Si-based alloy.Here, an inner fin can be placed inside of the tube 12. The inner fincan serve as a heat transfer member having a heat transfer surface widerthan an inner surface of the tube 12. The inner fin is brazed to theinner surface of the tube 12. Like the fin 14, a fillet corresponding tothe first fillet is formed in a braze joining portion in which the innerfin and the tube 12 join. The inner fin can employ various layerstructures and the tube 12 and the inner fin can be combined with eachother in various manners as the tube 12 and the fin 14 are combined.Further, a fin that meets a requirement met by the fin 14 as describedbelow is employed as the inner fin.

The header tank 16 of FIG. 1 includes a tank space 16 a communicatingwith the multiple tubes 12. Hence, the header tank 16 distributes fluidto the multiple tubes 12 and collects fluid from the multiple tubes 12.The header tank 16 includes a header plate 162, a tank body 164 and aseparator 166.

Here, as shown in FIG. 4, the header plate 162 is composed of a planaraluminum alloy having multiple through holes. The multiple tubes 12 areinserted into the multiple through holes, respectively, and are brazedto the header plate 162. Hence, in the claimed invention, the headerplate 162 corresponds to a tank member that includes a tank spacecommunicating with the multiple flow channel forming members.

As shown, at a braze joining portion 24, in which the tube 12 and theheader plate 162 join, a fillet 26 is again formed. In the claimedinvention, the fillet 26 corresponds to a second fillet in a brazejoining portion formed the flow channel forming member and the tankmember.

Each of the tube 12 and the header plate 162 may employ various layerstructures, and can be combined with each other in various manners asillustrated in FIGS. 5A to 5K, wherein a fillet 26 is omitted for thepurpose of simplicity. As shown in FIGS. 5A to 5K, at least one of thetube 12 and the header plate 162 includes a brazing material layer on asurface thereof.

In each of examples of FIGS. 5A to 5D, the tube 12 includes a corematerial layer 121 and two brazing material layer 122 and 123. In eachof examples of FIGS. 5E to 5H, the tube 12 includes a core materiallayer 121 and a brazing material layer 122. In each of examples of FIGS.5I to 5K, the tube 12 is composed only of a core material layer 121.

In each of the examples of FIGS. 5A and 5E, the header plate 162 iscomposed only of a core material layer 162 a. In each of examples ofFIGS. 5B, 5F and 5I, the header plate 162 includes a core material layer162 a and a brazing material layer 162 b. The brazing material layer 162b is located on an outside of the core material layer 162 a and theheader tank 16. In each of examples of FIGS. 5C, 5G and 5J, the headerplate 162 includes a core material layer 162 a and a brazing materiallayer 162 c. The brazing material layer 162 c is located on the corematerial layer 162 a facing the header tank space 16 a. In each ofexamples of FIGS. 5D, 5H and 5K, the header plate 162 includes a corematerial layer 162 a and two brazing material layers 162 b and 162 c.The core material layer 162 a is composed of an Al—Mn-based alloy. Eachof the brazing material layers 162 b and 162 c is composed of anAl—Si-based alloy.

As shown in FIG. 6, the tank body 164 is prepared by molding a planaraluminum alloy into a U-shape having a U-shaped cross-section. The tankbody 164 is brazed to the header plate 162 to form the tank space 16 a.Hence, in the claimed invention, the tank body 164 corresponds to ajoining member joined to the tank member.

Further, in a braze joining portion 28 in which the header plate 162 andthe tank body 164 join, a fillet 30 is formed. Hence, (in a claimedinvention), the fillet 30 corresponds to a third fillet in the brazejoining portion in which the tank member and the joining member joinwith each other.

The header plate 162 and the tank body 164 may employ various layerstructures and may be combined with each other in various manners asillustrated in FIGS. 7A to 7I, wherein a fillet 30 is omitted for thepurpose of simplicity. Specifically, as shown in each of examples ofFIGS. 7A to 7I, at least one of the header plate 162 and the tank body164 includes a brazing material layer on a surface thereof.

In each of the examples of FIGS. 7A to 7D, the header plate 162 includesa core material layer 162 a and a brazing material layer 162 b. In eachof examples of FIG. 7E to 7H, the header plate 162 includes the corematerial layer 162 a and two brazing material layers 162 b and 162 c. Ineach of examples of FIGS. 7I and 7J, the header plate 162 includes acore material layer 162 a and a brazing material layer 162 c. Further,in each of examples of FIGS. 7K and 7L, the header plate 162 includesonly a core material layer 162 a.

In each of the examples of FIGS. 7A, 7E, 7I and 7K, the tank body 164includes a core material layer 164 a and a brazing material layer 164 b.The brazing material layer 164 b is located on a surface of the corematerial layer 164 a facing the tank space 16 a. In each of the examplesof FIGS. 7B, 7F, 7I and 7L, the tank body 164 includes the core materiallayer 164 a and two brazing material layers 164 b and 164 c. The brazingmaterial layer 164 c is located on outer surfaces of the core materiallayer 164 a and the header tank 16, respectively. In each of examples ofFIGS. 7C and 7G, the tank body 164 includes a core material layer 164 aand a brazing material layer 164 c. However, in each of examples ofFIGS. 7D and 7H, the tank body 164 includes only a core material layer164 a The core material layer 164 a is composed of an Al—Mn-based alloy.Each of the brazing material layers 164 b and 164 c is composed of anAl—Si-based alloy.

Further, as shown in FIG. 8, a separator 166 is provided to separate aninternal space formed by the header plate 162 and the tank body 164 intoa tank space 16 a and the other space. The separator 166 is prepared bymachining a planar aluminum alloy. As shown, the separator 166 is brazedto the header plate 162 and the tank body 164. Hence, in the claimedinvention, since it is joined to the header plate 162, the separator 166corresponds to a joining member joined to the tank member.

Further, a fillet 34 is formed in a braze joining portion 32, in whichthe header plate 162 and the separator 166 join. Hence, in the claimedinvention, the fillet 34 corresponds to a third fillet in the brazejoining portion in which the tank member and the joining member.Further, a fillet 38 is also formed in a braze joining portion 36, inwhich the tank body 164 and the separator 166.

Each of the header plate 162 and the separator 166 may employ variouslayer structures and are combined with each other in various manners asillustrated in FIGS. 9A to 9F, wherein a fillet 34 is omitted for thepurpose of simplicity; Specifically, as shown in FIGS. 9A to 9F, atleast one of the header plate 162 and the separator 166 includes abrazing material layer on a surface thereof.

In each of examples of FIGS. 9A to 9D, the separator 166 includes a corematerial layer 166 a and two brazing material layers 166 b and 166 c. Ineach of examples of FIGS. 9E to 9F, the separator 166 includes only acore material layer 166 a The core material layer 166 a is composed ofan Al—Mn-based alloy; Each of the brazing material layers 164 b and 164c is composed of an Al—Si-based alloy; In each of the examples of FIGS.9A and 9E, the header plate 162 includes a core material layer 162 a andtwo brazing material layers 162 b and 162 c. In each of examples ofFIGS. 9B and 9F, the header plate 162 includes a core material layer 162a and a brazing material layer 162 c. Further, in an example of FIG. 9C,the header plate 162 includes a core material layer 162 a and a brazingmaterial layer 162 b. In an example of FIG. 9D, the header plate 162includes only a core material layer 162 a.

Further, as shown in FIG. 1, a laminated body is formed by alternatelystacking the tube 12 and the fin 14 multiple times in a given direction,and a pair of side plates 18 is disposed at both ends of the laminatedbody in the given direction to reinforce the laminated body. Each of theside plates 18 is prepared by machining a planar aluminum alloy.

As shown in FIG. 10, the pair of side plate 18 is inserted into thethrough hole formed in the header plate 162 and is brazed to the headerplate 162. Hence, in the claimed invention, the side plate 18corresponds to a joining member joined to a tank member. Further, afillet 42 is formed in a braze joining portion 40, in which the headerplate 162 and the side plate 18 join. Hence, in the claimed invention,the fillet 42 corresponds to a third fillet in the braze joining portionin which the tank member and the joining member join with each other.

Each of the header plate 162 and the side plate 18 may employ variouslayer structures and is combined with each other in various manners asillustrated in FIGS. 9A to 9F, wherein a fillet 42 is omitted for thepurpose of simplicity. Specifically, as shown in FIGS. 11A to 11G, atleast one of the header plate 162 and the side plate 18 includes abrazing material layer on a surface thereof.

In each of examples of FIGS. 11A to 11D, the side plate 18 includes acore material layer 181 and a brazing material layer 182. In each ofexamples of FIGS. 11E to 11G, the side plate 18 includes only a corematerial layer 181. The core material layer 181 is composed of anAl—Mn-based alloy. The brazing material layer 182 is composed of anAl—Si-based alloy.

In the example of FIG. 11A, the header plate 162 includes only a corematerial layer 162 a. In each of examples of FIGS. 11B and 11E, theheader plate 162 includes a core material layer 162 a and a brazingmaterial layer 162 b. In examples of FIGS. 11C and 11F, the header plate162 includes a core material layer 162 a and a brazing material layer162 c. In examples of FIGS. 11D and 11G, the header plate 162 includes acore material layer 162 a and two brazing material layers 162 b and 162c.

Further, the heat exchanger 10 of this embodiment of the presentdisclosure is produced by applying a brazing process without using fluxin an ambience of a lower oxygen concentration than the atmosphere ateither atmospheric pressure or a higher pressure than atmosphericpressure. Hence, the flux is excluded from the heat exchanger 10 of thisembodiment. As the ambience of the lower oxygen concentration than theatmosphere, an inert gas atmosphere can be exemplified.

Further, the heat exchanger 10 of this embodiment is produced to meetthe below described first to third conditions.

The first one is a plate thickness of each of components of the heatexchanger 10 as described below. First, an average plate thickness ofthe tube 12 is from 0.100 mm or more to 0.400 mm or less. An averagethickness of the fin 14 is from 0.025 mm or more to 0.150 mm or less. Anaverage thickness of the header plate 162 is from 0.500 mm or more to2.000 mm or less. An average thickness of each of the tank body 164, theseparator 166 and the side plate 18 is from 0.500 mm or more to 2.000 mmor less.

Here, the average thickness of each of the header plate 162, the tankbody 164, the separator 166 and the side plate 18 is greater than theaverage thickness of each of the tube 12 and the fins 14, respectively.Accordingly, in this embodiment, the header plate 162, the tank body164, the separator 166 and the side plate 18 act as thicker membersamong all structural elements of the heal exchanger 10. The tube 12 andthe fin 14 act as thinner members among all structural elements of theheat exchanger 10, respectively.

A second condition is a contained chemical element and a concentrationof a fillet as described below. That is, each of the fillets 22, 26, 30,34 and 42 is composed of an aluminum alloy containing magnesium (i.e.,Mg) and bismuth (i.e., Bi) and Silicon (i.e., Si). A concentration ofthe magnesium (hereinafter referred to as the Mg concentration) of eachof the fillets 22, 26, 30, 34 and 42 is from 0.2% or more to 2.0% orless by mass, and is preferably 0.3% or more by mass.

Here, the fillet 22 formed in the braze joining portion 20, in which thetube 12 and the fin 14 respectively acting as the thin members join actsas the first fillet. The fillet 26 formed in the braze joining portion24, in which the tube 12 and the header plate 162 respectively acting asthe thin and thick members join acts as the second fillet. The fillet 30formed in the braze joining portion 28, in which the header plate 162and the tank body 164 respectively acting as the thick members join actsas the third fillet. The fillet 34 formed in the braze joining portion32, in which the header plate 162 and the separator 166 respectivelyacting as the thick members join also acts as the third fillet. Thefillet 42 formed in the braze joining portion 40, in which the headerplate 162 and the side plate 18 respectively acting as the thick membersjoin also acts as the third fillet.

The third condition is a Mg concentration at a thickness center of astructural member having a brazing material layer as described below. Atleast one of the tube 12 and the fin 14 includes a brazing materiallayer 122 or 142 on a front surface thereof. As shown in FIGS. 3A and3B, when the tube 12 includes the brazing material layer 122 while thefin 14 does not, a Mg concentration of the tube 12 at its platethickness center is from 0.1% or more to 1.0% or less by mass. Bycontrast, as shown in FIGS. 3C and 3D, when the fin 14 includes thebrazing material layer 142 while the tube 12 does not, an Mgconcentration of the fin 14 at its plate thickness center is from 0.2%or more to 1.0% or less by mass. Further, as shown in FIGS. 3E and 3F,when both of the tube 12 and the fin 14 have brazing material layers 122and 142, respectively, a Mg concentration of the tube 12 at its platethickness center is from 0.1% or more to 1.0% or less by mass. At thesame time, an Mg concentration of the fin 14 at its plate thicknesscenter is from 0.2% or more to 1.0% or less by mass.

Further, as shown in FIGS. 12 and 13, when the tube 12 includes twobrazing material layers 122 and 123 before brazing, the brazing materiallayer 122 and 123 remain on the tube 12 even after brazing. The sameevent occurs in the remaining components (i.e., structures other thanthe tube 12) of the heat exchanger 10 as well. Accordingly, the averageplate thickness of each of the components includes a thickness of thebrazing layer remaining after brazing. By contrast, when each of thecomponents before brazing does not contain a brazing layer, thethickness of each of the components before and after brazing does notchange.

Here, an average thickness is measured based on a captured image of eachof sections of the components. That is, as shown in FIG. 14, on an imageof a section of each of the tube 12 and the header plate 162, twoparallel lines are respectively drawn along opposite sides of each ofthe tube 12 and the header plate 162 by using a common image analysismethod. An interval between these two parallel lines of each of the tube12 and the header plate 162 is measured as respective plate thicknessest1 and t2. Measurement of the thickness of each of the remainingstructural members is substantially the same.

As shown in FIGS. 15 and 16, the Mg concentration of the fillet ismeasured based on a line analysis of a section of each of the fillets 22and 26 by using an EPMA (Electron Probe Micro Analyzer). In the drawing,respective arrows D1 and D2 indicate typical directions along which theline analyses are applied. The analysis covers from one end to the otherend of the fillet in a given direction. As shown in FIG. 17, an averageof degrees of the Mg concentration measured based on the line analysiscorresponds to the Mg concentration of the fillet.

Further, a Mg concentration at a plate thickness center in each of thecomponents is measured by the EPMA based on the line analysis. As shownby arrow D3 in FIG. 14, a line analysis in applied in a plate thicknessdirection from one side to the other side of the tube 12. As shown inFIG. 18, an average of degrees of Mg concentration plotted in a range of±5 μm from a plate thickness center of the tube 12 corresponds to the Mgconcentration of the plate thickness center. In the remainingcomponents, the Mg concentration of the plate thickness center issimilarly obtained.

Here, the above-described second and third conditions are obtained as aresult of the below described testing executed in practical examples.

Further, when Mg is oxidized during brazing thereby forming an oxidefilm of the Mg on a surface of each of components, it is difficult toobtain a satisfactory braze. To solve such a problem, bismuth maysuppress formation of the Mg oxide film during brazing and is thusdesirably employed. Specifically, the bismuth is only needed in abrazing material layer and is not needed in a core material layer beforesoldering. As a result, however, the bismuth remains on the fillet afterbrazing.

Further, Mg destroys an oxide film of aluminum existing in a joinedsection during brazing. This enables satisfactory soldering. Hence, theMg is only needed in at least one of the brazing material layer and thecore material layer before brazing. Further, as a diffusion of achemical element during brazing, Mg spreads to the brazing materiallayer. As a result, the Mg remains in the fillet after brazing.

Further, to enable satisfactory soldering, the below described postbrazing conditions are to be met. That is, an Mg concentration of eachof the fillets 22, 26, 30, 34 and 42 is 0.2% or more by mass. When thetube 12 includes the brazing material layer 122, an Mg concentration ofthe tube 12 at its plate thickness center is 0.1% or more by mass. Whenthe fin 14 includes the brazing material layer 142, an Mg concentrationof the fin 14 at its plate thickness center is 0.2% or more by mass.That is, when respective Mg concentrations are lower than theabove-described values, preferable brazing cannot be obtained.Specifically, by including Mg in each of the component members 12, 14,162, 164, 166 and 18 before brazing to be able to meet theabove-described values, a heat exchanger 10 can be satisfactorilybrazed. Further, it is more preferable that each of the componentmembers 12, 14, 162, 164, 166 and 18 includes a given amount of Mgbefore brazing to enable each of the fillets 22, 26, 30, 34 and 42 tohave an Mg concentration of 0.3% or more by mass. With this, a heatexchanger 10 can be particularly satisfactorily brazed.

In the above, since erosion occurs when the Mg concentration of thefillet is 2.0% or more by mass, the Mg concentration of the fillet is2.0% or less. Here, the erosion is a phenomenon in that aluminumalloy-based material melts due to diffusion of a composition of brazingmaterial to the aluminum alloy material. Further, to similarly avoid theerosion, the Mg concentration of the tube 12 at its plate thicknesscenter is 1.0% or less by mass. Also, to similarly avoid the erosion,the Mg concentration of the fin 14 at its plate thickness center is 1.0%or less by mass.

Hence, as component members 12, 14, 162, 164, 166 and 18 of the heatexchanger 10 before brazing, components capable of meeting the abovedescribed first to third conditions after brazing are employed. Inaddition, in the environment of lower oxygen concentration than theatmosphere at either atmospheric pressure or a pressure higher thanatmospheric pressure, the heat exchanger 10 is brazed without usingflax. With this, three types of braze joining portions including thebraze joining portion in which two thin plates join, the braze joiningportion in which the thin and thick plates join and the braze joiningportion in which two thick plates join can be satisfactory formed.Specifically, the heat exchanger 10 can be satisfactorily brazed at thejoining portions.

Now, a second embodiment of the present disclosure is described withreference to FIG. 19A. As shown there, a tube 12 is formed by brazing aplate member subjected to a bending process.

That is, the tube 12 includes a core material layer 121, a brazingmaterial layer 124 and a cladding layer 125. The brazing material layer124 is located on one side of the core material layer 121. The brazingmaterial layer 124 is located on an outer surface of the tube 12. Thebrazing material layer 124 may composed of an Al—Si-based alloy. Thecladding layer 125 is located on the other side of the core materiallayer 121 opposite the brazing material layer 124. The cladding layer125 is thus located inside of the tube 12. The cladding layer 125 iscomposed of an aluminum alloy (i.e., not a brazing material), such asAl—Zn-based alloy, etc., for example. Further, as shown in FIG. 19A, ineach of regions R1 and R2 of the tube 12, the brazing material layer 124and the cladding layer 125 are joined together.

An Mg concentration in a surface layer of the cladding layer 125 islower than the Mg concentration of the tube 12 at a plate thicknesscenter of the tube 12. The surface layer of the cladding layer 125 is aregion having a depth of 10 micrometer from a surface of the claddinglayer 125. An Mg concentration in the surface layer of the claddinglayer 125 is measured based on a line analysis of a cross section of thetube 12 by using an EPMA. Here, as shown in FIG. 19B, if an oxide filmof Mg is formed on a surface of the cladding layer 125, a Mg thickenedlayer may be identified sometimes in the surface layer of the claddinglayer 125 during the EPMA line analysis. As shown in FIG. 19B, in whicha left edge of a horizontal axis corresponds to the surface of the tube12, the Mg thickened layer is a part of the tube 12 in the vicinity ofthe surface thereof, in which an Mg concentration rapidly increases dueto influence of an oxidation film of Mg. Hence, when the Mg thickenedlayer is present, the Mg concentration in the surface of the claddinglayer 125 is an average of degrees of Mg concentration of an innerregion distanced from a surface of the tube 12 by 10 μm by excluding theMg thickened layer.

Remaining configurations of the heat exchanger 10 of this embodiment ofthe present disclosure are substantially the same as the firstembodiment of the present disclosure. Because of this, variousadvantages obtained in the first embodiment can be similarly obtained inthis embodiment of the present disclosure. According to this embodimentof the present disclosure, formation of the oxide film on the surface ofthe cladding layer 125 can be effectively suppressed during brazing.With this, preferable brazing quality can be obtained at joiningportions of the tube 12.

Now, a third embodiment of the present disclosure is described withreference to FIG. 20. As shown in FIG. 20, a fin 15 is disposed insideof the tube 12. The tube 12 is brazed partially sandwiching the fin 15.

The tube 12 includes a core material layer 121, a brazing material layer126 and a cladding layer 127. The brazing material layer 126 is locatedon one side of the core material layer 121. The brazing material layer126 is located on an inner side of the tube 12. The brazing materiallayer 126 is composed of an Al—Si-based alloy. The cladding layer 127 islocated on a side of the core material layer 121 opposite the brazingmaterial layer 126. The cladding layer 127 is composed of an aluminumalloy excluding brazing material, for example, an Al—Zn-based alloy. Thefin 15 may consist of the core material layer 151 composed of anAl—Mn-based alloy.

As shown in FIG. 20, in a region R3 of the tube 12, the brazing materiallayer 126 and the cladding layer 127 are joined together. As in thesecond embodiment, an Mg concentration in a surface layer of thecladding layer 127 is lower than the Mg concentration of the tube 12 ata plate thickness center of the tube 12.

Remaining configurations of the heat exchanger 10 of this embodiment ofthe present disclosure is substantially the same as the first embodimentof the present disclosure. Because of this, various advantages obtainedin the first and second embodiment can be similarly obtained in thisembodiment of the present disclosure.

Now, a fourth embodiment of the present disclosure is described withreference to FIG. 21. As shown in FIG. 21, a tube 12 includes a corematerial layer 121, a brazing material layer 126 and a cladding layer127. The cladding layer 127 is located on a core material layer 121 toface an outer fin 14. An inner fin 15 is placed inside of the tube 12.The fin 15 consists of a core material layer 151. The fin 15 and thebrazing material layer 126 of the tube 12 are joined together. The fin14 includes a core material layer 141 and two brazing material layers142 and 143. The brazing layers 142 and 143 of the fin 14 and thecladding layer 127 of the tube 12 are joined to each other. In FIG. 21,the brazing material layer 142 and the cladding layer 127 are joined 142together.

In this embodiment of the present disclosure, as a pre-brazing tube 12,a tube that employs a core material layer 121 with an Mg concentrationof 0.1% or more by mass and the cladding layer 127 with an Mgconcentration of 0.1% or less by mass is utilized. Before brazing, theMg concentration of the cladding layer 127 is lower than that of thecore material layer 121. Whereas in a post brazing tube 12, an Mgconcentration in a surface layer of the cladding layer 127 is lower thanthat of the tube 12 at its plate thickness center.

Remaining configurations of the heat exchanger 10 of this embodiment ofthe present disclosure are substantially the same as those of the firstembodiment of the present disclosure. Because of this, variousadvantages obtained in the first embodiment of the present disclosurecan be similarly obtained in this embodiment of the present disclosure.In addition, in this embodiment, the Mg concentration in the surfacelayer of the cladding layer 127 is lower than the Mg concentration ofthe tube 12 at its plate thickness center. That is, as a pre-brazingtube 12, a tube 12 enabled to lower the Mg concentration in the surfaceof the cladding layer 127 than that of the tube 12 at its platethickness center after brazing is used. With this, formation of an oxidefilm on the surface of the cladding layer 127 can be reduced duringbrazing. Hence, the tube 12 and the fin 14 are satisfactorily brazed atjoining portions.

Now, a fifth embodiment of the present disclosure is described hereinbelow with reference to FIG. 3A or 3B. In this embodiment of the presentdisclosure, as shown in FIG. 3A or 3B, a tube 12 includes a corematerial layer 121 and a brazing material layer 122. A fin 14 iscomposed of a bare member 141 with its a core material exposed outside.That is, the fin 14 includes neither a brazing material layer nor acladding layer. Further, the brazing material layer 122 of the tube 12and the fin 14 as the bare member 141 are joined together. Further, anMg concentration of the fin 14 at its plate thickness center is 0.1% orless by mass. In this embodiment, the tube 12 corresponds to one of aflow channel forming member and a heat transfer member. The fin 14corresponds to the other one of the flow channel forming member and theheat transfer member.

Remaining configurations of the heat exchanger 10 of this embodiment ofthe present disclosure are substantially the same as those of the firstembodiment of the present disclosure. Since the heat exchanger 10 ofthis embodiment meets the above-described first to third conditions metby that of the first embodiment, similar advantages can be also obtainedin this embodiment as obtained in the first embodiment of the presentdisclosure.

In addition, in this embodiment, an Mg concentration of the fin 14 atits plate thickness center is 0.1% or less by mass, formation of theoxide film of Mg on the surface of the fins 14 can be suppressed duringbrazing. Hence, the tube 12 and the fin 14 are satisfactorily brazed intheir joining portions.

Now, a sixth embodiment of the present disclosure is described withreference to FIG. 3C. In this embodiment, as shown in FIG. 3C, a tube 12is configured only by a core material layer 121. That is, the tube 12includes neither a brazing material layer nor a cladding layer. In otherwords, the tube 12 is configured by a bare member 121 with its corematerial exposed. The tube 12 illustrated in FIG. 3C is either a seamwelded pipe or an extruded perforated pipe. A fin 14 includes a corematerial layer 141 and two brazing material layers 142 and 143. Thebrazing layer 142 (143) of the fin 14 and the bare member of the tube 12are joined together. Further, an Mg concentration of the tube 12 at itsplate thickness center is 0.1% or less by mass. In this embodiment, thefin 14 corresponds to one of a flow channel forming member and a heattransfer member. The tube 12 corresponds to the other one of the flowchannel forming member and the heat transfer member.

Remaining configurations of the heat exchanger 10 of this embodiment ofthe present disclosure are substantially the same as those of the firstembodiment of the present disclosure. Hence, since the heat exchanger 10of this embodiment meets the above-described first to third conditionsmet by that of the first embodiment, similar advantages can also beobtained in this embodiment as obtained in the first embodiment of thepresent disclosure.

In addition, in this embodiment, an Mg concentration of the tube 12 atits plate thickness center is 0.1% or less by mass, formation of theoxide film of Mg on the surface of the tube 12 can be suppressed duringbrazing. Hence, the tube 12 and the fin 14 are satisfactorily brazed intheir joining portions.

Now, a seventh embodiment of the present disclosure is described withreference to FIGS. 22A to 22D. Different from the heat exchanger 10 ofthe first embodiment, a heat exchanger 10 of this embodiment is preparedby adding zinc (i.e., Zn) to a surface of the tube 12 in various mannersas illustrated FIGS. 22A to 22D, wherein a fillet is mitted.

Specifically, in an example of FIG. 22A, a tube 12 includes a corematerial layer 121, a brazing material layer 122 and a cladding layer128. The cladding layer 128 lies on an opposite side of a core materiallayer 121 to a side thereof on which a brazing material layer 122 lies(i.e., a side facing a fin 14). The cladding layer 128 is composed of analuminum alloy, such as Al—Zn-based alloy, etc., excluding brazingmaterial, for example. The fin 14 may consist of a core material layer141. The brazing material layer 122 of the tube 12 and the core materiallayer 141 of the fin 14 are joined together.

Further, in an example of FIG. 22B, a tube 12 includes a core materiallayer 121, a brazing material layer 122 and a cladding layer 128 as inthe example of FIG. 22A. However, unlike the example of FIG. 22A, thefin 14 includes a core material layer 141 and two brazing materiallayers 142 and 143. Hence, the brazing material layer 122 of the tube 12and one of the brazing material layers 142 and 143 of the fin 14 may bejoined together.

Further, in an example of FIG. 22C, a tube 12 includes a core materiallayer 121, a brazing material layer 123 and a cladding layer 129 again.The cladding layer 129 lies on an opposite side of the core materiallayer 121 (i.e., a side thereof facing the fin 14) to a side thereof onwhich the brazing material layer 123 lies. The cladding layer 129 iscomposed of an aluminum alloy, such as Al—Zn-based alloy, etc.,excluding brazing material, for example. The fin 14 includes a corematerial layer 141 and two brazing material layers 142 and 143. Hence,the cladding layer 129 of the tube 12 and one of the brazing materiallayers 142 and 143 of the fin 14 may be joined together.

Further, in an example of FIG. 22D, the tube 12 includes a core materiallayer 121 and two cladding layers 128 and 129. The fin 14 includes acore material layer 141 and two brazing material layers 142 and 143.Hence, the cladding layer 129 of the tube 12 and one of the brazingmaterial layers 142 and 143 of the fin 14 may be joined together.

In addition, in each of the examples of FIG. 22A to 22D, a potentialdifference of 50 mV or more is created in the tube 12 in a platethickness direction of the tube 12. This potential difference is adifference between highest and lowest voltages generated in the tube 12in the plate thickness direction thereof as shown in FIG. 23. As shownin FIG. 23, a potential is lowest on a surface of the tube 12. In somecases, however, the potential becomes lowest at a portion other than thesurface of the tube 12.

Since remaining configurations of the heat exchanger 10 of thisembodiment of the present disclosure are substantially the same as thoseof the first embodiment of the present disclosure, similar advantagescan be obtained in this embodiment as obtained in the first embodimentof the present disclosure. In addition, according to this embodiment,since the potential difference of 50 mV or more is created in the tube12 in the thickness direction thereof, the heat exchanger 10 can providea high corrosion resistance as described later with reference to variouspractical examples.

Further, unlike this embodiment of the present disclosure, when a heatexchanger is brazed by using a vacuum brazing method, Zn contained in acladding layer generally evaporates. Hence, a potential created afterbrazing of the tube 12 is lower than 50 mV.

By contrast, the heal exchanger 10 of this embodiment is brazed in anenvironment of a lower oxygen concentration than the atmosphere ateither atmospheric pressure or a higher pressure than atmosphericpressure. Accordingly, an amount of evaporation of Zn from the claddinglayer can be decreased, while enabling to make a potential difference of50 mV or more.

Further, although Zn is added to the cladding layer 128 (129) accordingto this embodiment, Zn can be contained in the brazing material layer122 when the tube 12 includes the brazing material layer 122. Further,when the tube 12 includes a brazing material layer 123, the brazingmaterial layer 123 can contain Zn as well.

Now, an eighth embodiment of the present disclosure is described withreference to FIG. 24. As shown in FIG. 24, a heat exchanger 50 of thisembodiment is a laminate type heat exchanger prepared by laminatingmultiple plates. The heat exchanger 50 includes first and secondmultiple plates 52 and 54, first and second multiple fins 56 and 58, tworeinforcement plates 60 and 62 and a pipe 64. Each of these multipleplates 52 and 54, multiple fins 56 and 58, two reinforcement plates 60and 62 and the pipe 64 are composed of an aluminum alloy.

These first and second multiple plates 52 and 54 act as flow channelforming members to form first flow channels 51 a in which first fluidsflow and second flow channels 51 b in which second fluids flow,respectively. These multiple plates 52 and 54 are alternately laminatedin a given direction to alternately form the first and second flowchannels. Hence, the heat exchanger 50 exchanges heats of the firstfluids flown through the first flow channels 51 a and the second fluidsflown through the second flow channels 51 b.

Hence, the first flow channel 51 a is formed between the first plate 52and the second plate 54. The second flow channel 51 b is formed betweenthe second plate 54 and another first plate 52. Also, another first flowchannel 51 a is also formed between yet another first plate 52 locatedat one end of a stack of multiple plates 52 and 54 in a stackingdirection and the reinforcement plate 62. The first flow channel 51 acommunicates with an inner space of the pipe 64.

The first and second multiple fins 56 and 58 act as heat transfermembers with heat transfer surfaces wider than respective surfaces ofthe multiple plates 52 and 54. These first and second multiple fins 56and 58 enhance performance of heat transfer between the first fluids andthe second fluids. Each of the first and second multiple fins 56 and 58is a corrugated fin prepared by molding a plate into a waved shape. Eachof the multiple fins 56 and 58 can be molded into another shape than thewaved shape Here, the multiple first fins 56 are located in the multiplefirst flow channels 51 a, respectively. The multiple second fins 58 arelocated in the multiple second flow channels 51 b, respectively.

As shown in FIG. 25, the first fin 56 is brazed to the first plate 52and the second plate 54. Multiple fillets 68 a and 68 b are formed in ajoining portion 66 a, in which the first fin 56 and the first plate 52join and a joining portion 66 b, in which the first fin 56 and thesecond plate 54 join, respectively. Hence, in the claimed invention,each of these fillets 68 a and 68 b corresponds to the first filletformed in a braze joining portion in which the heat transfer member andthe flow channel forming member join with each other.

Although not illustrated, the second fin 58 is also brazed to the firstplate 52 and the second plate 54. Multiple fillets are similarly formedin a joining portion in which the second fin 58 and the first plate 52join and another joining portion in which the second fin 58 and thesecond plate 54 join, respectively. Hence, in the claimed invention, thefillet corresponds to the first fillet formed in a braze joining portionin which the heat transfer member and the flow channel forming memberjoin with each other.

Further, each of the first and second plates 52 and 54 and the first andsecond fins 56 and 58 may employ various layer structures, and combinedwith each other in various manners as illustrated in FIGS. 26A to 26E,wherein only the first plate 52 and the first fin 56 are illustrated andthe fillet 68 a is not illustrated. Specifically, as shown in FIGS. 26Ato 26E, at least one of the plate 52 (54) and the fin 56 (58) includes abrazing material layer on a surface thereof.

In an example of FIG. 26A, the first plate 52 is composed only of a corematerial layer 521. A first fin 56 includes a core material layer 561and two brazing material layers 562 and 563. These two brazing materiallayers 562 and 563 are located on both sides of the core material layer561. Hence, the core material layer 521 of the first plate 52 and thebrazing material layer 562 of the first fin 56 are brazed thereby joinedtogether.

In an example of FIG. 26B, the first plate 52 includes a core materiallayer 521 and a brazing material layer 522. The brazing material layer522 is located on one side of the core material layer 521. A first fin56 is substantially the same as the example of FIG. 26A. The brazingmaterial layer 562 of the first plate 52 and the brazing material layer522 of the first fin 56 are joined together.

In an example of FIG. 26C, a first plate 52 includes a core materiallayer 521 and two brazing material layers 522 and 523. The brazingmaterial layer 523 is located on an opposite side of the core materiallayer 521 to a side thereof on which the brazing material layer 522 islaminated. A first fin 56 is substantially the same as that in theexample of FIG. 26A. Hence, the brazing material layer 522 of the firstplate 52 and the brazing material layer 562 of the first fin 56 arejoined together.

In an example of FIG. 26D, a first plate 52 is substantially the same asthat in the example of FIG. 26B. A first fin 56 is composed only of acore material layer 561. Hence, the brazing material layer 522 of thefirst plate 52 and the core material layer 561 of the first fin 56 arejoined together.

In an example of FIG. 26D, a first plate 52 is substantially the same asthat in the example of FIG. 26B. A first fin 56 is composed only of acore material layer 561. Hence, the brazing material layer 522 of thefirst plate 52 and the core material layer 561 of the first fin 56 arejoined to together.

In an example of FIG. 26E, a first plate 52 is substantially the same asthat in FIG. 26C. A first fin 56 is substantially the same as that inFIG. 26D. Hence, the brazing material layer 522 of the first plate 52and the core material layer 561 of the first fin 56 are joined totogether.

Here, these core material layers 561 of the first plate 52 and the firstfin 56 are composed of Al—Mn-based alloy s, respectively. The brazingmaterial layers 522 and 523 of the first plate 52 and the brazingmaterial layers 562 and 563 of the first fin 56 are composed ofAl—Si-based alloys, respectively. Further, each the first plate 52 andthe second fin 58, the second plate 54 and the first fin 56 and thesecond plate and the second fin 58 may have various layer structures,and may be combined in substantially the same manner as combined inFIGS. 26A to 26E.

Further, yet another example is described with reference to FIG. 24.That is, two reinforcement plates 60 and 62 are provided as shown inFIG. 24 to act as reinforcing members to collectively reinforce a stackof laminated multiple plates 52 and 54. The reinforcement plate 60located on one side of the stack of the multiple laminated plates 52 and54 in a given direction is brazed to the first plate 52 located on theone side thereof. The other reinforcement plate 62 located on the otherend of the stack of laminated plates 52 and 54 in the given direction isbrazed to the first plate 52 located on the other end of the stack oflaminated plates 52 and 54 in the given direction. Between the otherreinforcement plate 62 and the first plate 52, a first flow channel 51 ais formed.

Further, as shown in FIG. 27, in a braze joining portion 70 formed bythe first plate 52 and the reinforcement plate 60, a fillet 72 isformed. In the claimed invention, the fillet 72 corresponds to a secondfillet formed in a braze joining portion formed by a flow channelforming member and a reinforcing member. Further, although not shown, inas braze joining portion formed by the first plate 52 and the secondreinforcement plate 62, a fillet corresponding to a second fillet in theclaimed invention is formed.

Here, each of the first plate 52 and the reinforcement plate 60 mayemploy various layer structures and may be combined with each other invarious manners as shown in FIGS. 28A to 28J, wherein the fillet 72 isnot shown. Specifically, as shown in FIGS. 28A to 28J, at least one ofthe first plate 52 and the reinforcement plate 60 includes a brazingmaterial layer on a surface thereof.

In examples of FIG. 28A to 28C, the first plate 52 includes a corematerial layer 521 and a brazing material layer 523. The brazingmaterial layer 523 is located on a surface of the core material layer521 facing the reinforcement plate 60. In each of examples of FIGS. 28Dand 28E, a first plate 52 is composed only of a core material layer 521.In each of examples of FIGS. 28F to 28H, a first plate 52 includes acore material layer 521 and two brazing material layers 522 and 523. Thebrazing material layer 522 is located on an opposite side of the corematerial layer 521 to a side thereof facing the reinforcement plate 60.In each of examples of FIGS. 281 to 28J, a first plate 52 includes acore material layer 521 and a brazing material layer 522.

In each of examples of FIGS. 28A to 28F, one of reinforcing members 60is composed only of a core material layer 601. Where as in examples ofFIGS. 28B, 28D, 28G and 28I, the reinforcing member 60 includes a corematerial layer 601 and a brazing material layer 602. The brazingmaterial layer 602 is located on a side of the core material layer 601facing the first plate 52. In examples of FIGS. 28C, 28E, 28H and 28J, areinforcing member 60 includes a core material layer 601 and two brazingmaterial layers 602 and 603. The brazing material layer 603 is locatedon an opposite side of the core material layer 601 to a side thereoffacing the first plate 52. The core material layer 601 is composed of anAl—Mn-based alloy. The brazing material layers 602 and 603 are composedof Al—Si-based alloys, respectively.

Further, a pipe 64 shown in FIG. 24 accommodates a flow channelcommunicating with the first flow channel 51 a. The pipe 64 is brazed tothe reinforcement plate 60 located on the one end of the stack.Accordingly, in the claimed invention, the pipe 64 corresponds to ajoining member joined to the reinforcing member. Further, as shown inFIG. 29, a fillet 76 is formed in a braze joining portion 74 formed bythe reinforcement plate 60 of the one end of the stack and the pipe 64.Hence, in the claimed invention, the fillet 76 corresponds to a thirdfillet formed in a braze joining portion formed by a reinforcing memberand a joining member.

Here, each of the reinforcement plate 60 and the pipe 64 may employvarious layer structures and may be combined with each other in variousmanners as illustrated in FIGS. 30A to 30L, wherein the fillet 76 is notshown. As shown in FIGS. 30A to 30L, at least one of the reinforcementplate 60 and the pipe 64 includes a brazing material layer on a surfacethereof.

In each of examples of FIG. 30A to 30D, a reinforcement plate 60 locatedon the one end of the stack includes a core material layer 601 and abrazing material layer 602. The brazing material layer 602 is located ona side of the core material layer 601 facing the pipe 64. In each ofexamples of FIG. 30E to 30H, a reinforcement plate 60 located on oneside of the stack includes a core material layer 601 and two brazingmaterial layers 602 and 603. The brazing material layer 603 is locatedon an opposite side of the core material layer 601 to a side thereoffacing the pipe 64. In examples of FIGS. 301 and 30J, a reinforcementplate 60 located on one end of the stack includes a core material layer601 and a brazing material layer 603. Further, in each of examples ofFIGS. 30K and 30L, a reinforcement plate 60 located on one end of thestack is composed only of a core material layer 601.

Further, in each of the examples of FIGS. 30A, 30E, 30I and 30K, thepipe 64 includes the core material layer 641 and the brazing materiallayer 642. The brazing material layer 642 is located on a side of thecore material layer 641 facing the reinforcement plate 60. In each ofthe examples of FIGS. 30B, 30F, 30J and 30L, the pipe 64 includes thecore material layer 641 and two brazing material layers 642 and 643. Thebrazing material layer 643 is located on an opposite side of the corematerial layer 641 to a side thereof facing the reinforcement plate 60.In each of examples of FIGS. 30C and 30G, the pipe 64 includes the corematerial layer 641 and the brazing material layer 643. In each of theexamples of FIGS. 30D and 30H, the pipe 64 is composed only of the corematerial layer 641. The core material layer 641 is composed of anAl—Mn-based alloy. The brazing material layers 642 and 643 are composedof Al—Si-based alloys, respectively.

Further, like the heat exchanger 10 of the first embodiment of thepresent disclosure, the heat exchanger 10 of this embodiment is producedby using a brazing process without applying flax in an ambience of alower oxygen concentration than the atmosphere at either atmosphericpressure or a higher pressure than atmospheric pressure. Accordingly,the flux is absent in the heat exchanger 50 of this embodiment of thepresent disclosure.

Further, the heal exchanger 50 of this embodiment of the presentdisclosure may satisfy the below described fourth to sixth conditions.

First, a plate thickness of each of components of the heat exchanger 50meets the fourth condition as described below. That is, an averagethickness of each of the first and second plates 52 and 54 is from 0.200mm or more to 0.600 mm or less. An average thickness of each of thefirst and second fins 56 and 58 is from 0.025 mm or more to 0.150 mm orless. An average thickness of each of the reinforcement plates 60 and 62is greater than 0.600 mm and is 2.000 mm or less. Further, an averagethickness of the pipe 64 is greater than 0.600 mm and is 2.000 mm orless.

Thus, the average plate thickness of each of the reinforcement plates 60and 62 and the pipe 64 is greater than that of the first and secondplates 52 and 54 and the first and second fins 56 and 58. Accordingly,the reinforcement plates 60 and 62 and the pipe 64 are relativelythicker members among the components of the heat exchanger 50. Bycontrast, the first and second plates 52 and 54 and the first and secondfins 56 and 58 are relatively thinner members among the components ofthe heat exchanger 50.

The fifth condition relates to contained chemical elements in a filletand these concentrations as described below. That is, each of thefillets 68 a, 68 b, 72 and 76 is composed of an aluminum alloycontaining Mg, Bi and Si. An Mg concentration of each of the fillets 68a, 68 b, 72 and 76 is from 0.2% or more to 2.0% or less, and ispreferably 0.3% or more by mass.

Hence, in the claimed invention, each of the fillets 68 a and 68 bformed in the braze joining portions 66 a and 66 b formed by the firstand the second plates 52 and 54 and the first and second fins 56 and 58,respectively, corresponds to a first fillet formed in a braze joiningportion formed by thin members. Further, in the claimed invention, thefillet 72 formed in the braze joining portion 70 formed by the firstplate 52 and the reinforcement plate 60 located at one aid of the stackcorresponds to a second fillet formed in a braze joining portion formedby a thin member and a thick member. Further, in the claimed invention,the fillet 76 formed in the braze joining portion 74 formed by thereinforcement plate 60 located at one end of the stack and the pipe 64corresponds to a third fillet formed in a braze joining portion formedby thick members.

Now, the sixth condition relating to a Mg concentration at a platethickness center of each of components having a brazing material layeris herein described. That is, at least one of the plates 52 (or 54) andthe fin 56 (or 58) has a brazing material layer 522 or 562 (or 563) on asurface thereof. As shown in FIGS. 26D and 26E, when the plate 52 (54)has the brazing material layer 522 while the fin 56 (58) does not havethe brazing material layer, the Mg concentration of the plate 52 (54) atits plate thickness center thereof is from 0.1% or more to 1.0% or lessby mass. Further, as shown in FIG. 26A, when the fin 56 (58) has thebrazing material layer 562 (563) while the plate 52 (54) does not havethe brazing material layer, the Mg concentration of the fin 56 (58) atthe plate thickness center is from 0.2% or more to 1.0% or less by mass.Further, as shown in FIGS. 26B and 26C, when both of the plate 52 (54)and the fin 56 (58) have brazing material layers 522 and 562 (or 563), aMg concentration of the plate 52 (54) at the plate thickness center isfrom 0.1% or more to 1.0% or less by mass. Further, a Mg concentrationof the fin 56 (58) at the plate thickness center thereof is from 0.2% ormore to 1.0% or less by mass.

Here, a method of measuring the average thickness, that of measuring theMg concentration of the fillet, and that of measuring the Mgconcentration at the plate thickness center are substantially the sameas those employed in the first embodiment of the present disclosure.

Hence, due to meeting the 4th condition in the heat exchanger 50,according to this embodiment, the thin members, the thin member and thethick member and the thick members are joined together, respectively.Further, since the fifth and sixth concentrations are substantially thesame as the second and third concentrations met by the first embodiment,the same advantage can be obtained in this embodiment as obtain by thefirst embodiment.

Now, a ninth embodiment of the present disclosure is described hereinbelow with reference to FIG. 31. As shown in FIG. 31, a heat exchanger50A of this embodiment is different from the heat exchanger 50 of theeighth embodiment in that a second flow channel 51 b is not sealed and asecond fin 58 is excluded. Further, in the heat exchanger 50A of thisembodiment, one end of a first fin 56 is sandwiched by a first plate 52and a second plate 54. In this state, the first plate 52, the secondplate 54 and the first fin 56 are brazed together. Further, in the heatexchanger 50A of this embodiment, instead of the reinforcement plate 62of the eighth embodiment, a third plate 55 is used as one of multipleplates. Hence, the third plate 55 collectively forms a first flowchannel 51 a together with the first plate 52 there between.Accordingly, in the claimed invention, the third plate 55 corresponds toa flow channel forming member to form a flow channel.

As shown in FIG. 25, fillets 68 a and 68 b are formed in braze joiningportions formed by the plate 52 and 54 (55) and the fin 56 as firstfillets, respectively. Further, each of the plates 52 and 54 (55) andeach of the fins 56 and 58 may employ various layer structures and maybe combined with each other in various manners as shown in FIGS. 26A to26E like the eighth embodiment.

Further, as shown in FIG. 32, the first plate 52 and a reinforcementplate 60 are brazed together. In a braze joining portion 70 formed bythe first plate 52 and the reinforcement plate 60, a fillet 72 is formedas a second filet. Further, the first plate 52 and the reinforcementplate 60 may employ various layer structures and are combined with eachother in substantially the same manner as in the eighth embodiment.

Further, as shown in FIG. 33, a pipe 64 is brazed to the reinforcementplate 60. In a joining portion 74 formed by the reinforcement plate 60and the pipe 64, a fillet 76 is formed as a third fillet. Further, thereinforcement plate 60 and the pipe 64 may employ various layerstructures and are combined with each other in the same manner as in theeighth embodiment.

Further, the first plate 52 and the pipe 64 are brazed together. In abraze joining portion 78 formed by the first plate 52 and the pipe 64, afillet 80 is formed.

Remaining configurations of the heat exchanger 50A of this embodimentare substantially the same as the heat exchanger 50 of the eighthembodiment. Accordingly, in this embodiment of the present disclosure,substantially the same advantage obtained in the eighth embodiment canbe obtained.

Now, a tenth embodiment of the present disclosure is described hereinbelow with reference to FIG. 34. In this embodiment, a relation betweenan Mg concentration in a surface of a cladding layer 127 and an Mgconcentration of a tube 12 at its plate thickness center is differentfrom that in the fourth embodiment. That is, as shown in FIG. 34,according to this embodiment, a fin 14 includes a core material layer141 and brazing material layers 142 and 143 as that in the fourthembodiment. The tube 12 includes a core material layer 121 and acladding layer 127. The cladding layer 127 of the tube 12 and thebrazing material layer 142 (143) of the fin 14 are joined together.However, different from the fourth embodiment, the tube 12 does not havethe brazing material layer in this embodiment. Further, in thisembodiment, unlike the fourth embodiment, as a tube 12 before brazing, atube composed of a core material layer 121 having an Mg concentrationranging from 0% or more to 0.1% or less by mass, and a cladding layer127 having an Mg concentration ranging from 0% or more to 0.1% or lessby mass is used. As a result of brazing, the Mg concentration in thesurface layer of the cladding layer 127 is either the same or different(i.e., lower or higher) than the Mg concentration of the tube 12 at itsplate thickness center. In any situation, however, the Mg concentrationin the surface layer of the cladding layer 127 is from 0% or more to0.1% or less.

Remaining configurations of the heat exchanger 10 of this embodiment ofthe present disclosure are substantially the same as those of the firstembodiment of the present disclosure. Because of this, variousadvantages obtained in the first embodiment of the present disclosurecan be similarly obtained in this embodiment of the present disclosure.Further, according to this embodiment, since the tube that enables theMg concentration in the surface layer of the cladding layer 127 to rangefrom 0% or more to 0.1% or less by mass after brazing is used as thetube 12 before brazing. Hence, formation of an oxide film of Mg on thesurface of the cladding layer 127 can be suppressed during brazing.Hence, the tube 12 and the fin 14 are satisfactorily brazed in a joiningportion in which the tube 12 and the fin 14 join.

Further, this embodiment can be applied to each of the heat exchangers50 and 50A of the eighth and ninth embodiments, respectively. In such asituation, the tube 12 of this embodiment is replaced with each of themultiple plates 52 and 54. Also, each of the multiple fins 56 and 58 isreplaced with the fin 14 as well. In such a situation, advantagesobtained in this embodiment can be similarly obtained.

Herein below; various modifications of the above-described embodimentsof the present disclosure are described. First, the fourth embodiment ofthe present disclosure may be applied to the heat exchangers 50 and 50Aof the respective eighth and ninth embodiments of the presentdisclosure. In such a situation, each of the multiple plates 52 and 54in each of the eighth and ninth embodiments of the present disclosure isreplaced with the tube 12 of the fourth embodiment. Also, each of themultiple fins 56 and 58 is replaced with the fin 14. Further, like thefourth embodiment, each of the multiple plate 52 and 54 also has thecladding layer 127 in this modification. Since an Mg concentration inthe surface layer of the cladding layer 127 is lower than the Mgconcentration of each of the multiple plates 52 and 54 at its platethickness center, substantially the same advantage can be obtained as inthe fourth embodiment.

Secondly, the fifth embodiment of the present disclosure may be appliedto the heat exchangers 50 and 50A of the respective eighth and ninthembodiments of the present disclosure. In such a situation, each of themultiple plates 52 and 54 in each of the eighth and ninth embodiments ofthe present disclosure is replaced with the tube 12 of the fifthembodiment. Also, each of the multiple fins 56 and 58 is replaced withthe fin 14. Like the fifth embodiment, the multiple fins 56 and 58 arecomposed of bare members, respectively. An Mg concentration of each ofthe multiple fins 56 and 58 at its plate thickness center is 0.1% bymass. Because of this, substantially the same advantage can be obtainedin this modification as in the fifth embodiment.

Thirdly, the sixth embodiment of the present disclosure may be appliedto the heat exchangers 50 and 50A of the respective eighth and ninthembodiments of the present disclosure. In such a situation, each of themultiple plates 52 and 54 in each of the eighth and ninth embodiments ofthe present disclosure is replaced with the tube 12 of the sixthembodiment. Also, each of the multiple fins 56 and 58 is replaced withthe fin 14. Like the sixth embodiment, the multiple fins 52 and 54 arecomposed of bare members, respectively. An Mg concentration of each ofthe multiple fins 52 and 54 at its plate thickness center is 0.1% bymass. Because of this, substantially the same advantage can be obtainedin this modification as in the sixth embodiment.

Fourthly, the seventh embodiment of the present disclosure may beapplied to the heat exchangers 50 and 50A of the eighth and ninthembodiments of the present disclosure, respectively. In such asituation, each of the multiple plates 52 and 54 in each of the eighthand ninth embodiments of the present disclosure is replaced with thetube 12 of the seventh embodiment. Also, each of the multiple fins 56and 58 is replaced with the fin 14. Like that in the seventh embodiment,Zinc is added to a surface of the multiple plates 52 and 54 in thismodification as well. Also, in each of the multiple plates 52 and 54, apotential difference of 50 mV is created in each of the multiple plate52 and 54 in a plate thickness direction thereof. Because of this,substantially the same advantage can be obtained in this modification asin the seventh embodiment.

Fifthly, although the tank body 164 of the heat exchanger 10 is composedof the aluminum alloy in each of the first to seventh embodiments, thetank body 164 can be made of synthetic resin as shown in FIG. 35.

Sixthly, in the heat exchanger 50A of the ninth embodiment, the firstfin 56 is placed in the first flow channel 51 a, while any fin is notplaced in the second flow channel 51 b. However, the second fin 58 maybe placed in the second flow channel 51 b, while any fin may not beplaced in the first flow channel 51 a by contrast as shown in FIG. 36.Also, as shown in FIG. 37, the first fin 56 can be placed in the firstflow channel 51, while the second fin 58 can be placed in the secondflow channel 51 b.

Seventhly, in the above-described various embodiments of the presentdisclosure, the core material layer is composed of the Al—Mn-basedalloy. However, the core material layer can be composed of anotheraluminum alloy. Further, in the above-described various embodiments ofthe present disclosure, the cladding layer is composed of theAl—Zn-alloy. However, the cladding layer can be composed of anotheraluminum alloy as well. In such a situation, the cladding layer of theseventh embodiment of the present disclosure is made of aluminum alloycontaining zinc.

Now, various practical examples of the present invention are describedherein below.

Initially, measurement and evaluation of first to 46th practicalexamples and first to 33rd comparative examples are described withreference to applicable tables. That is, the applicant has evaluatedbrazing quality of each of testing samples of first to 46th practicalexamples and first to 33rd comparative examples as shown in first totenth tables. Here, the first to 30th practical examples correspond tothe first and eighth embodiments of the present disclosure. Hereinbelow, a configuration of each of the testing samples, brazingprocessing and a method of evaluation executed after brazing areinitially described.

First, a configuration of each of the testing samples is described. Asthe testing samples, multiple plate members respectively having variousthicknesses are prepared. Each of the testing samples includes a corematerial layer and a brazing material layer stacked on the core materiallayer. The core material layer is composed of an Al—Mn-based alloy. Thebrazing material layer is composed of an Al—Si—Bi-based alloy. In eachof the testing samples, Mg is added to at least one of the brazingmaterial layer and the core material layer. A thickness of each of thetesting samples, an amount of addition of Mg to each of the corematerial layer and the brazing material layer are shown in the first toseventh tables.

Further, a brazing process is performed as described below.Specifically, multiple assembly structures are prepared by assemblingtesting samples as plate members and respective counterpart membersacting as joining partners. The counterpart member is a plate memberexcluding the brazing material layer and is composed of an aluminumalloy. Then, the assembly structure is heated in a nitrogen ambience atatmospheric pressure. In this way, the testing samples and thecounterpart members are brazed without using flux.

Further, in this brazing process, as a heat input amount, one of large,medium and small levels is selected. Regardless of a size of the heatinput amount, temperature is raised at a first temperature rising speedfrom 60 degree Celsius to 560 degree Celsius. The temperature is furtherraised at a second temperature rising speed from 560 degree Celsius tothe maximum degree of temperature. The maximum degree of temperature ismaintained for a given period after temperature has been raised.Subsequently, from the maximum degree of temperature is lowered down to560 degree Celsius at a first heat temperature descending speed. Thetemperature is further lowered from 560 degree Celsius to 60 degreeCelsius at a second temperature lowering speed. Each of the first heatraising speed, the maximum degree of temperature, the maximum degree oftemperature maintaining period, and the second temperature loweringspeed is equally used in each of situations in which the heat inputamount is small, medium and large. Further, when the input amount ofheat is large, a relatively slow-speed is set for each of the secondheat raising speed and the first heat raising speed (i.e., a temperaturerising speed is low). By contrast, when the heat input amount is small,a relatively high speed is set for each of the second heat raising speedand the first heat raising speed (i.e., a temperature rising speed ishigh). When the heat input amount is medium, a medium speed is set foreach of the second heat raising speed and the first heat raising speedas w ell.

Now, various results of evaluation of brazing are herein below describedwith reference applicable tables. Specifically, brazing quality isevaluated based on a determination if a fillet is formed in anassembling structure after brazing as well as quality of the fillet.Further, a remaining plate thickness, an Mg concentration at a platethickness center, and an Mg concentration of a fillet of each of thetesting samples after heating are also measured. Various results ofevaluation of the brazing quality and measurement are obtained as shownin first to seventh tables.

In the tables, a sign x indicates that a fillet is intermittently formedaround a joining portion. Thus, the sign x in the table indicates thatbrazing quality is defective. By contrast, a sign AA in the tableindicates that a fillet is continuously formed around the joiningportion. Thus, the sign AA in the table indicates that brazing qualityis satisfactory. Further, a sign AAA in the table also indicates that afillet is continuously formed around the joining portion. Besides, thesign AAA in the table indicates that a size of a fillet is substantiallythe same as a fillet obtained when brazed by using a conventional methodof so-called Nokolok with flux. Hence, the sign AAA indicates thatbrazing quality is almost excellent.

The first table is herein below described.

FIRST TABLE After brazing Before brazing Mg Amount of Mg Amount of MgConcentration Mg Plate added to brazing added to core Remaining at plateConcentration Brazing heat thickness material layer material layer Platethickness thickness center of fillet Brazing input amount (mm) (mass %)(mass %) (mm) (mass %) (mass %) quality Comparative Small 0.030 1.00.028 0.1 0.2 X example 1 Comparative Medium 0.030 1.0 0.028 0.1 0.1 Xexample 2 Comparative Large 0.030 1.0 0.028 0.1 0.1 X example 3Comparative Small 0.030 — 0.1 0.028 0.1 0.1 X example 4 ComparativeMedium 0.030 — 0.1 0.028 0.1 0.1 X example 5 Comparative Large 0.030 —0.1 0.028 0.1 0.1 X example 6 Comparative Small 0.030 — 0.2 0.028 0.10.2 X example 7 Comparative Medium 0.030 — 0.2 0.028 0.1 0.1 X example 8Comparative Large 0.030 — 0.2 0.028 0.1 0.1 X example 9 Practical Small0.030 — 0.3 0.028 0.2 0.3 AAA example 1 Practical Medium 0.030 — 0.30.028 0.2 0.2 AA example 2 Practical Large 0.030 0.3 0.028 0.2 0.2 AAexample 3

As shown, the first table indicates a result of measurement andevaluation of a testing sample having a plate thickness of 0.030 mmbefore brazing. As shown in the first table, brazing quality of each offirst to ninth comparative examples is defective. By contrast, brazingquality of each of first to third practical examples is satisfactory. Inthis situation, a remaining plate thickness is 0.028 mm. An Mgconcentration at a plate thickness center after heating is 0.2% by mass.An Mg concentration of a fillet is from 0.2% or more to 0.3% or less bymass. Brazing quality of the third practical example is particularlyexcellent. In this situation, an Mg concentration of a fillet is 0.3% bymass.

The second table is herein below described.

SECOND TABLE After brazing Before brazing Mg Amount of Mg Amount of MgConcentration Mg Plate added to brazing added to core Remaining at plateConcentration Brazing heat thickness material layer material layer Platethickness thickness center of fillet Brazing input amount (mm) (mass %)(mass %) (mm) (mass %) (mass %) quality Comparative Large 0.050 — 0.10.046 0.1 0.1 X example 10 Comparative Large 0.050 — 0.2 0.046 0.1 0.1 Xexample 11 Practical Large 0.050 — 0.4 0.046 0.3 0.2 AA example 4Practical Large 0.050 — 0.6 0.046 0.4 0.3 AAA example 5 Practical Large0.050 — 0.8 0.046 0.5 0.5 AAA example 6 Practical Small 0.050 1.0 1.00.046 0.8 1.1 AAA example 7 Practical Medium 0.050 1.0 1.0 0.046 0.7 0.5AAA example 8 Practical Large 0.050 1.0 1.0 0.046 0.6 0.6 AAA example 9

As shown, the second table indicates a result of evaluation andmeasurement of a testing sample having a thickness of 0.050 mm beforebrazing. As shown in the second table, brazing quality of each of tenthto eleventh comparative examples is defective. By contrast, brazingquality of each of fourth to ninth practical examples is satisfactory.In this situation, a remaining plate thickness is 0.046 mm. An Mgconcentration at a plate thickness center after heating is from 0.3% ormore to 0.8% or less by mass. An Mg concentration of a fillet is from0.2% or more to 1.1% or less by mass. As shown, brazing quality of eachof fifth to ninth practical examples is particularly excellent. In thissituation, an Mg concentration of a fillet is from 0.3% or more to 1.1%or less by mass.

The third table is herein below described.

THIRD TABLE After brazing Before brazing Mg Amount of Mg Amount of MgConcentration Mg Plate added to brazing added to core Remaining at plateConcentration Brazing heat thickness material layer material layer Platethickness thickness center of fillet Brazing input amount (mm) (mass %)(mass %) (mm) (mass %) (mass %) quality Comparative Small 0.100 1.0 —0.092 0.0 0.3 X example 12 Comparative Medium 0.100 1.0 — 0.092 0.0 0.1X example 13 Comparative Large 0.100 1.0 — 0.092 0.0 0.1 X example 14Comparative Medium 0.100 — 0.1 0.092 0.1 0.1 X example 15 ComparativeMedium 0.100 — 0.2 0.092 0.2 0.1 X example 16 Practical Medium 0.100 —0.4 0.092 0.4 0.2 AA example 10 Practical Medium 0.100 — 1.0 0.092 0.90.6 AAA example 11 Practical Small 0.100 0.3 0.3 0.092 0.3 0.4 AAAexample 12 Practical Medium 0.100 0.3 0.3 0.092 0.3 0.2 AA example 13Practical Large 0.100 0.3 0.3 0.092 0.2 0.2 AA example 14

As shown, the third table indicates a result of evaluation andmeasurement of a testing sample having a thickness of 0.100 mm beforebrazing. As shown in the third table, brazing quality of each of twelfthto 16th comparative examples is defective. By contrast, brazing qualityof each of tenth to 14th practical examples is satisfactory. In thissituation, a remaining plate thickness is 0.092 mm. An Mg concentrationat a plate thickness center after heating is from 0.2% or more to 0.9%or less by mass. An Mg concentration of a fillet is from 0.2% or more to0.6% or less. As shown, brazing quality of each of eleventh to twelfthpractical examples is particularly excellent. In this situation, an Mgconcentration of a fillet is from 0.4% or more to 0.6% or less.

The fourth table is herein below described.

FOURTH TABLE After brazing Before brazing Mg Amount of Mg Amount of MgConcentration Mg Plate added to brazing added to core Remaining at plateConcentration Brazing heat thickness material layer material layer Platethickness thickness center of fillet Brazing input amount (mm) (mass %)(mass %) (mm) (mass %) (mass %) quality Comparative Medium 0.150 — 0.10.138 0.1 0.1 X example 17 Comparative Medium 0.150 — 0.2 0.138 0.2 0.1X example 18 Practical Medium 0.150 — 0.4 0.138 0.4 0.2 AA example 15Practical Medium 0.150 — 1.0 0.138 1.0 0.6 AAA example 16 ComparativeSmall 0.150 0.1 0.1 0.138 0.1 0.1 X example 19 Practical Small 0.150 0.20.2 0.138 0.2 0.3 AAA example 17 Practical Small 0.150 0.3 0.3 0.138 0.30.4 AAA example 18

As shown, the fourth table indicates a result of evaluation andmeasurement of a testing sample having a thickness of 0.150 mm beforebrazing. As shown in the fourth table, brazing quality of each of 17thto 19th comparative examples is defective. By contrast, brazing qualityof each of 15th to 18th practical examples is satisfactory. In thissituation, a remaining plate thickness is 0.138 mm. An Mg concentrationat a plate thickness center after heating is from 0.2% or more to 1.0%or less by mass. An Mg concentration of a fillet is from 0.2% or more to0.6% or less by mass. As shown, brazing quality of each of 16th to 18thpractical examples is particularly excellent. In this situation, an Mgconcentration of a fillet is from 0.3% or more to 0.6% or less by mass.

The fifth table is herein below described.

FIFTH TABLE After brazing Before brazing Mg Amount of Mg Amount of MgConcentration Mg Plate added to brazing added to core Remaining at plateConcentration Brazing heat thickness material layer material layer Platethickness thickness center of fillet Brazing input amount (mtn) (mass %)(mass %) (mm) (mass %) (mass %) quality Comparative Large 0.200 1.0 —0.184 0.0 0.1 X example 20 Comparative Large 0.200 — 0.1 0.184 0.1 0.1 Xexample 21 Comparative Large 0.200 — 0.2 0.184 0.2 0.1 X example 22Practical Large 0.200 — 0.4 0.184 0.4 0.2 AA example 19 Practical Large0.200 — 0.6 0.184 0.6 0.3 AAA example 20 Practical Large 0.200 — 1.00.184 1.0 0.6 AAA example 21 Practical Small 0.200 1.0 1.0 0.184 1.0 1.4AAA example 22

As shown, the fifth table indicates a result of evaluation andmeasurement of a testing sample having a thickness of 0.200 mm beforebrazing. As shown in the fifth table, brazing quality of each of 20th to22th comparative examples is defective. By contrast, brazing quality ofeach of 19th to 22th practical examples is satisfactory. In thissituation, a remaining plate thickness is 0.184 mm. An Mg concentrationat a plate thickness center after heating is from 0.4% or more to 1.0%or less by mass. An Mg concentration of a fillet is from 0.2% or more to1.4% or less by mass. As shown, brazing quality of each of 20th to 22thpractical examples is particularly excellent. In this situation, an Mgconcentration of a fillet is from 0.3% or more to 1.4% or less by mass.

The sixth table is herein below described.

SIXTH TABLE After brazing Before brazing Mg Amount of Mg Amount of MgConcentration Mg Plate added to brazing added to core Remaining at plateConcentration Brazing heat thickness material layer material layer Platethickness thickness center of fillet Brazing input amount (mm) (mass %)(mass %) (mm) (mass %) (mass %) quality Comparative Large 0.400 1.00.368 0.0 0.3 X example 23 Comparative Medium 0.400 — 0.1 0.368 0.1 0.1X example 24 Comparative Medium 0.400 — 0.2 0.368 0.2 0.1 X example 25Practical Medium 0.400 — 1.0 0.368 1.0 0.7 AAA example 23 ComparativeSmall 0.400 — 0.1 0.368 0.1 0.1 X example 26 Practical Small 0.400 0.11.0 0.368 0.1 0.2 AA example 24 Practical Small 0.400 0.5 1.0 0.368 0.10.5 AAA example 25

As shown, the sixth table indicates a result of evaluation andmeasurement of a testing sample having a thickness of 0.400 mm beforebrazing. As shown in the sixth table, brazing quality of each of 23th to26th comparative examples is defective. By contrast, brazing quality ofeach of 23th to 25th practical examples is satisfactory. In thissituation, a remaining plate thickness is 0.368 mm. An Mg concentrationat a plate thickness center after heating is from 0.1% or more to 1.0%or less by mass. An Mg concentration of a fillet is from 0.2% or more to0.7% or less by mass. As shown, brazing quality of each of 23th and 25thpractical examples is particularly excellent. In this situation, an Mgconcentration of a fillet is from 0.5% or more to 0.7% or less by mass.

A seventh table is herein below described.

SEVENTH TABLE After brazing Before brazing Mg Amount of Mg Amount of MgConcentration Mg Plate added to brazing added to core Remaining at plateConcentration Brazing heat thickness material layer material layer Platethickness thickness center of fillet Brazing input amount (mm) (mass %)(mass %) (mm) (mass %) (mass %) quality Comparative Large 0.600 1.0 —0.552 0.0 0.5 X example 27 Comparative Large 0.600 — 0.1 0.552 0.1 0.1 Xexample 28 Comparative Large 0.600 — 0.2 0.552 0.2 0.1 X example 29Practical Large 0.600 — 0.4 0.552 0.4 0.3 AAA example 26 Practical Large0.600 — 0.6 0.552 0.6 0.4 AAA example 27 Practical Large 0.600 — 0.80.552 0.8 0.5 AAA example 28 Practical Large 0.600 — 1.0 0.552 1.0 0.6AAA example 29 Practical Small 0.600 0.1 0.1 0.552 0.1 0.2 AA example 30

As shown, the seventh table indicates a result of evaluation andmeasurement of a testing sample having a thickness of 0.600 mm beforebrazing. As shown in the seventh table, brazing quality of each of 27thto 29th comparative examples is defective. By contrast, brazing qualityof each of 26th to 30th practical examples is satisfactory. In thissituation, a remaining plate thickness is 0.552 mm. An Mg concentrationat a plate thickness center after heating is from 0.1% or more to 1.0%or less by mass. An Mg concentration of a fillet is from 0.2% or more to0.6% or less by mass. As shown, brazing quality of each of 26th to 29thpractical examples is particularly excellent. In this situation, an Mgconcentration of a fillet is from 0.3% or more to 0.6% or less by mass.

An eighth table is herein below described.

EIGHT TABLE After brazing Before brazing Mg Amount of Mg Amount of MgConcentration Mg Plate added to brazing added to core Remaining at plateConcentration Brazing heat thickness material layer material layer Platethickness thickness center of fillet Brazing input amount (mm) (mass %)(mass %) (mm) (mass %) (mass %) quality Comparative Large 0.700 — 0.10.644 0.1 0.1 X example 30 Comparative Large 0.700 — 0.2 0.644 0.2 0.1 Xexample 31 Practical Large 0.700 — 0.4 0.644 0.4 0.2 AA example 31Practical Large 0.700 — 0.6 0.644 0.6 0.4 AAA example 32 Practical Large0.700 — 1.0 0.644 1.0 0.6 AAA example 33 Practical Small 0.700 0.1 0.10.644 0.1 0.2 AA example 34 Practical Small 0.700 0.2 0.2 0.644 0.2 0.3AAA example 35

As shown, the eighth table indicates a result of evaluation andmeasurement of a testing sample having a thickness of 0.700 mm beforebrazing. As shown in the eighth table, brazing quality of each of 30thto 31th comparative examples is defective. By contrast, brazing qualityof each of 31th to 35th practical examples is satisfactory. In thissituation, a remaining plate thickness is 0.644 mm. An Mg concentrationat a plate thickness center after heating is from 0.1% or more to 1.0%or less by mass. An Mg concentration of a fillet is from 0.2% or more to0.6% or less by mass. As shown, brazing quality of each of 32th, 33thand 35th practical examples is particularly excellent. In thissituation, an Mg concentration of a fillet is from 0.3% or more to 0.6%or less by mass.

A ninth table is herein below described.

NINTH TABLE After brazing Before brazing Mg Amount of Mg Amount of MgConcentration Mg Plate added to brazing added to core Remaining at plateConcentration Brazing heat thickness material layer material layer Platethickness thickness center of fillet Brazing input amount (mm) (mass %)(mass %) (mm) (mass %) (mass %) quality Practical Medium 1.000 1.0 —0.920 0.0 0.8 AAA example 36 Comparative Medium 1.000 — 0.2 0.920 0.20.1 X example 32 Practical Medium 1.000 — 0.5 0.920 0.5 0.3 AA example37 Practical Medium 1.000 — 1.0 0.920 1.0 0.5 AAA example 38 PracticalMedium 1.000 1.0 0.5 0.920 0.5 1.0 AAA example 39 Practical Medium 1.0001.0 1.0 0.920 1.0 1.3 AAA example 40 Practical Medium 1.000 0.5 1.00.920 1.0 0.9 AAA example 41

As shown, the ninth table indicates a result of evaluation andmeasurement of a testing sample having a thickness of 1.000 mm beforebrazing. As shown in the ninth table, brazing quality of a 32thcomparative example is defective. By contrast, brazing quality of eachof 36th to 41th practical examples is satisfactory. In this situation, aremaining plate thickness is 0.920 mm. An Mg concentration of a filletis from 0.3% or more to 1.3% or less by mass. As shown, brazing qualityof each of 36th and 38th to 41th practical examples is particularlyexcellent. In this situation, an Mg concentration of a fillet is from0.5% or more to 1.3% or less by mass.

Further, as a result of measurement and evaluation of each of 37th to41th practical examples, a Mg concentration at a plate thickness centerafter heating is from 0.5% or more to 1.0% or less by mass. Further, anMg concentration of a fillet is from 0.3% or more to 1.3% or less bymass.

A tenth table is herein below described.

TENTH TABLE Before brazing After brazing Amount of Mg Mg added to Amountof Mg Concentration Mg Plate brazing added to core Remaining at plateConcentration Brazing heat thickness material layer material layer Platethickness thickness center of fillet Brazing input amount (mm) (mass %)(mass %) (mm) (mass %) (mass %) quality Practical Medium 2.000 1.0 —1.840 0.0 0.8 AAA example 42 Comparative Medium 2.000 1.0 0.2 1.840 0.20.1 X example 33 Practical Medium 2.000 — 0.5 1.840 0.5 0.2 AA example43 Practical Medium 2.000 — 0.5 1.840 0.5 1.0 AAA example 44 PracticalMedium 2.000 1.0 1.0 1.840 1.0 1.2 AAA example 45 Practical Medium 2.0000.5 1.0 1.840 1.0 0.8 AAA example 46

As shown, the tenth table indicates a result of evaluation andmeasurement of a testing sample having a thickness of 2.000 mm beforebrazing. As shown in the tenth table, brazing quality of a 33thcomparative example is defective. By contrast, brazing quality of eachof 42th and 43th to 46th practical examples are satisfactory. In thissituation, a remaining plate thickness is 1.840 mm. An Mg concentrationof a fillet is from 0.2% or more to 1.2% or less by mass. Brazingquality of each of 42th and 44th to 46th practical examples isparticularly excellent. In this situation, an Mg concentration of afillet is from 0.8% or more to 1.2% or less by mass.

Further, as a result of measurement and evaluation of each of 43th to46th practical examples, a Mg concentration at a plate thickness centerafter heating is from 0.5% or more to 1.0% or less by mass. Further, anMg concentration of a fillet is from 0.2% or more to 1.2% or less bymass.

Hence, as understood from the first to fourth tables, to obtainpreferable brazing quality when the remaining plate thickness is from0.025 mm or more to 0.150 mm or less, it is only needed that the Mgconcentration of the fillet is 0.2% or more by mass and the Mgconcentration at the plate thickness center is from 0.2% or more to 1.0%or less by mass. To further obtain excellent brazing quality, it is onlyneeded that the Mg concentration of the fillet is 0.3% or more by mass.

Further, as understood from the fourth to sixth tables, to obtainpreferable brazing quality when the remaining plate thickness is from0.100 mm or more to 0.400 mm or less, it is only needed that the Mgconcentration of the fillet is 0.2% or more by mass and the Mgconcentration at the plate thickness center is from 0.1% or more to 1.0%or less by mass. Further, to obtain excellent brazing quality, it isonly needed that the Mg concentration of the fillets is 0.3% or more bymass.

Further, as understood from the sixth to seventh tables, to obtainpreferable brazing quality when the remaining plate thickness is from0.200 mm or more to 0.600 mm or less, it is only needed that the Mgconcentration of the fillet is 0.2% or more by mass and the Mgconcentration at the plate thickness center is from 0.1% or more to 1.0%or less by mass. Further, to obtain excellent brazing quality, it isonly needed that the Mg concentration of the fillet is 0.3% or more bymass.

Further, as understood from the seventh to tenth tables, to obtainpreferable brazing quality when the remaining plate thickness is from0.500 mm or more to 2.000 mm or less, it is only needed that the Mgconcentration of the fillet is 0.2% or more by mass. Further, to obtainexcellent brazing quality, it is only needed that the Mg concentrationof the fillet is 0.3% or more by mass. Further, substantially the sameevaluation result may be obtained when the remaining plate thickness isgreater than 0.600 mm and is 2.000 mm or less.

However, as seen in the 36th and 42th practical examples, when theremaining plate thickness is greater than 0.500 mm and is 2.000 mm orless, the Mg concentration of the fillet sometimes becomes 0.2% or moreby mass even if the Mg concentration at the plate thickness center is 0%by mass. Since a preferable brazing quality can be obtained as far as anMg concentration of a fillet is 0.2% or more by mass, an Mgconcentration at a plate thickness center is not necessarily 0.1% ormore by mass. Substantially the same evaluation result may be obtainedwhen the remaining plate thickness is greater than 0.600 mm and is 2.000mm or less.

Here. Mg has a nature of easily spreading to a molten brazing materiallayer during brazing. Hence, regardless of a value of remaining platethickness, an upper limit of an Mg concentration of the fillet sometimesexceeds a value shown in the table. However, it has been known fromanother test that erosion occurs when an Mg concentration of the filletis greater than 2.0% by mass. Hence, to avoid such a problem, it isenough that the Mg concentration of the fillet is 2.0% or less by mass.

Now, a result of measurement and evaluation of each of 47th to 51thpractical examples and 34th to 36th comparative examples is describedwith reference to an applicable table. That is, the applicant also hasevaluated brazing quality of each of testing samples of 47th to 51thpractical examples and 34th to 36th comparative examples as shown in aneleventh table. Here, the 47th to 51th practical examples correspond tothe second to fourth embodiments of the present disclosure,respectively. Herein below, a configuration of each of the testingsamples, brazing processing applied to each of the testing samples and amethod of evaluation after brazing of each of the testing samples areinitially described.

First, a configuration of each of the testing samples is as follows. Asthe testing samples, plate members each functioning as a flow channelforming member are prepared. Each of the testing samples includes a corematerial layer and a cladding layer made of given material excludingbrazing material stacked on the core material layer. The core materiallayer is composed of an Al—Mn-based alloy. The cladding layer iscomposed of an Al—Si—Bi-based alloy. In each of the testing samples, Mgis added to each to the core material layer and the cladding layer.

Further, as a counterpart member serving as a joining counterpart foreach of the testing samples, a plate material having a core materiallayer and a brazing material layer stacked on the core material layer isprepared. The core material layer is composed of an Al—Mn-based alloy.The brazing material layer is composed of an Al—Si—Bi-based alloy. Mg isadded to the core material layer before brazing to enable an Mgconcentration of a fillet to be 0.2% or more by mass after the brazing.

A brazing process is performed as described below. Specifically,multiple assembly structures are assembled by connecting testing sampleswith respective counterpart members. In this situation, the claddinglayer of each of the testing samples is contacted to a brazing materiallayer as the counterpart member. Then, like the first to 46th practicalexample, the assembly structures are heated in a nitrogen ambience atatmospheric pressure. A brazing heat profile is the same as obtainedwhen heat input is small.

Now, a result of evaluation of brazing is herein below described withreference to applicable table. That is, brazing quality is evaluatedlike the first to 46th practical example. Further, a remaining platethickness, an Mg concentration at a plate thickness center, and an Mgconcentration of a cladding layer of each of the testing samples afterheating are also measured. A method of measuring the remaining thicknessand Mg concentration is substantially the same as employed in theabove-described practical example. Various results of evaluation of thebrazing quality and measurement are shown in an eleventh table. Here, aremaining plate thickness of each of the testing samples after heatingis 0.184 mm.

An eleventh table is herein below described.

ELEVENTH TABLE Mg Mg Concentration Concentration at plate in surfacelayer thickness center of cladding layer Brazing (mass %) (mass %)quality Comparative 1.0 1.0 X example 34 Practical 1.0 0.5 AA example 47Practical 1.0 0.1 AAA example 48 Comparative 0.2 0.2 X example 35Practical 0.2 0.1 AAA example 49 Practical 0.2 0.05 AAA example 50Comparative 0.1 0.1 X example 36 Practical 0.1 0.05 AA example 51

As shown in the eleventh table, brazing quality of each of 34th to 36thcomparative examples is defective. That is, in each of the 34th to 36thcomparative examples, an Mg concentration of a surface layer of thecladding layer is substantially the same as an Mg concentration of aplate thickness center. By contrast, brazing quality of each of 47th to51th practical examples is satisfactory. That is, in each of the 47th to51th practical examples, an Mg concentration of a surface layer of thecladding layer is lower than an Mg concentration of a plate thicknesscenter. Hence, it is realized that when the cladding layer is joined tothe brazing material layer, an Mg concentration of a surface layer of acladding layer after brazing is desirably lower than an Mg concentrationat a plate thickness center of a flow channel forming member.

Now, measurement and evaluation of 52th to 56th practical examples and a37th comparative example are described with reference to an applicabletable. That is, the applicant also has evaluated a brazing quality ofeach of testing sample of the 52th to 56th practical examples and the37th comparative example as shown in twelfth table. Here, the 52th to56th practical examples correspond to the tenth embodiment of thepresent disclosure. Herein below, a configuration of each of the testingsamples, brazing processing and a method of evaluation after brazing aredescribed.

First, each of testing samples is configured as described below. As thetesting samples, plate members each functioning as a flow channelforming member are prepared. A thickness of each of the testing samplesbefore brazing is 0.2 mm. Each of the testing samples includes a corematerial layer and a cladding layer made of given material excludingbrazing material stacked on the core material layer. The core materiallayer is composed of an Al—Mn-based alloy. The cladding layer iscomposed of an Al—Si—Bi-based alloy. In the 53th practical example, Mgis added to the core material layer before brazing and is not added tothe cladding layer before brazing. In the 55th practical example, Mg isnot added to the core material layer before brazing and is added to thecladding layer before brazing. In the 56th practical example, Mg isadded to each to the core material layer and the cladding layer beforebrazing.

Further, as a counterpart member serving as a joining counterpartjoining each of the testing samples, a plate material having a corematerial layer and a brazing material layer stacked on the core materiallayer is prepared. The core material layer is composed of an Al—Mn-basedalloy. The brazing material layer is composed of an Al—Si—Bi-basedalloy. Mg is added to the core material layer before brazing to enablean Mg concentration of a fillet to be 0.2% or more by mass after thebrazing.

A brazing process is performed as described below. Specifically, each ofmultiple assembly structures is assembled by connecting each of testingsamples with each of counterpart members, respectively. In thissituation, the cladding layer of the testing sample is contacted to abrazing material layer acting as the counterpart member. Subsequently,like the first to 46th practical example, the assembly structure isheated in a nitrogen ambience at atmosperic pressure. Further, a brazingheat profile is the same as used when heat input is small.

Further, a result of evaluation of brazing is obtained as herein belowdescribed with reference to applicable table. That is, brazing qualityis evaluated like the first to 46th practical example. Further, aremaining plate thickness, an Mg concentration at a plate thicknesscenter, and an Mg concentration of a cladding layer of the testingsample after heating are also measured. A method of measuring theremaining thickness and an Mg concentration is substantially the same asemployed in the above-described embodiment of the present disclosure.With this, various results of evaluation of the brazing quality andmeasurement are obtained as shown in a twelfth table. Here, a remainingplate thickness of the testing sample after heating is 0.184 mm.

A twelfth table is herein below described.

TWELFTH TABLE Mg Mg Concentration Concentration at plate in surfacelayer thickness center of cladding layer Brazing (mass %) (mass %)quality Practical 0.1 0.05 AA example 52 Practical 0.1 0.0 AAA example53 Comparative 0.05 0.5 X example 37 Practical 0.05 0.1 AA example 54Practical 0.0 0.1 AA example 55 Practical 0.0 0.0 AAA example 56

As shown in the twelfth table, brazing quality of 37th comparativeexample is defective. That is, in the 37th comparative example, an Mgconcentration in a surface layer of the cladding layer is 0.5% and isgreater than an Mg concentration at a plate thickness center. Bycontrast, brazing quality of each of 52th to 56th practical examples issatisfactory. That is, in each of the 52th to 56th practical examples, aMg concentration in a surface layer of the cladding layer is from 0% ormore to 0.1% or less by mass. Hence, it is realized that when thecladding layer is joined to the brazing material layer, an Mgconcentration in a surface layer of the cladding layer after brazing isdesirably 0% or more to 0.1% or less by mass.

A result of measurement and evaluation of each of 61th to 62th practicalexamples and a 61th comparative example is obtained as described hereinbelow with reference to an applicable table. That is, the applicant alsohas evaluated a brazing quality of each of testing samples of the 61thto 62th practical examples and the 61th comparative example as shown inthirteenth table. Here, the 61th to 62th practical examples collectivelycorrespond to the fifth embodiment of the present disclosure. Aconfiguration of each of the testing samples, brazing processing appliedto each of the testing samples, and a method of evaluation of each ofthe testing samples after brazing are described herein below.

First, each of testing samples is configured as described below. Astesting samples, multiple tubes and fins configured substantially in thesame manner as in the fifth embodiment of the present disclosure areprepared. A thickness of each of the fins as prepared is 0.03 mm. Thefin is a bare member composed only of a core material layer composed ofan Al—Mn-based alloy. A thickness of each of the prepared tubes is 0.2mm. This tube includes a core material layer and a brazing materiallayer stacked on the core material layer. The core material layer iscomposed of an Al—Mn-based alloy. The brazing material layer is composedof an Al—Si—Bi-based alloy. Mg is added to the core material layer(before brazing) to enable a Mg concentration of a fillet to be 0.2% ormore by mass after brazing and a Mg concentration at a plate thicknesscenter thereof to be 0.1% or more by mass after brazing as well.

A brazing process is performed as described below. First, a fin and atube are assembled thereby collectively forming an assembly structure.Subsequently, like the first to 30th practical example, the assemblystructure is heated in a nitrogen ambience at atmospheric pressure. Abrazing heat profile is the same as used when heat input is small.

A result of evaluation of brazing is obtained as herein below describedwith reference to applicable table. That is, brazing quality isevaluated like the first to 46th practical example. Also, likeevaluation of the first to 46th practical example, a remaining platethickness, a Mg concentration at a plate thickness center after heatingare measured again. Various results of evaluation of the brazing qualityand measurement are obtained as shown in a thirteenth table. Here, aremaining plate thickness of each of the tubes after heating is 0.184mm.

A thirteenth table is herein below described.

FOURTEENTH TABLE Mg Mg Concentration at plate Concentration thicknesscenter (mass %) of fillet Brazing Fin Tube (mass %) quality Comparative0.5 ≥0.1 ≥0.2 X example 61 Practical 0.1 ≥0.1 ≥0.2 AA example 61Practical 0 ≥0.1 ≥0.2 AAA example 62

As shown in the thirteenth table, brazing quality of 61th comparativeexample is defective. That is, in the 61th comparative example, an Mgconcentration of the fin is 0.5% by mass at a plate thickness centerthereof. By contrast, brazing quality of each of 61th to 62th practicalexamples is satisfactory. That is, in each of the 61th to 62th practicalexamples, an Mg concentration of the fin at the plate thickness centerthereof is from 0% or more to 0.1% or less by mass. Hence, it isrealized that when the fin is composed of the bare member, an Mgconcentration of the fin at a plate thickness center thereof desirablyis from 0% or more to 0.1% or less by mass.

A result of measurement and evaluation of each of 63th to 64th practicalexamples and a 62th comparative example is obtained as herein describedwith reference to an applicable table. That is, the applicant also hasevaluated brazing quality of each of testing samples of the 63th to 64thpractical examples and the 62th comparative example as shown in 14thtable. Here, the 63th to 64th practical examples collectively correspondto the sixth embodiment of the present disclosure. Herein below, aconfiguration of each of the testing samples, brazing processing appliedto each of the testing samples and a method of evaluation of each of thetesting samples after brazing are described.

First, each of testing samples is configured as described below. Thatis, as testing samples, tubes and fins similarly configured as in thesixth embodiment are prepared. A thickness of each of the tubes asprepared is 0.2 mm. This tube is a bare member composed only of a corematerial layer composed of an Al—Mn-based alloy. Further, a thickness ofthe fin as prepared is 0.03 mm. This fin includes a core material layerand brazing material layers respectively stacked on both sides of thecore material layer. The core material layer is composed of anAl—Mn-based alloy. The brazing material layer is composed of anAl—Si—Bi-based alloy. Mg is added to the core material layer (beforebrazing) to enable a Mg concentration of a fillet to be 0.2% or more bymass after brazing and a Mg concentration at a plate thickness centerthereof to be 0.2% or more by mass after the brazing as well.

A brazing process and evaluation after brazing are obtained as describedherein below. That is, a brazing process, evaluation after brazing andrespective measurements are substantially the same as executed in thepractical examples 61 and 62. Results of evaluation of brazing andrespective measurements are obtained as shown in a 14th table. Here, aremaining plate thickness of the fin after heating is 0.028 mm.

A fourteenth table is herein below described.

FOURTEENTH TABLE Mg Mg Concentration at plate Concentration thicknesscenter (mass %) of fillet Brazing Fin Tube (mass %) quality Comparative≥0.2 0.5 ≥0.2 X example 62 Practical ≥0.2 0.1 ≥0.2 AA example 63Practical ≥0.2 0 ≥0.2 AAA example 64

As shown in the 14th table, brazing quality of 62th comparative exampleis defective. That is, in the 62th comparative example, an Mgconcentration of the tube is 0.5% by mass at a plate thickness centerthereof. By contrast, brazing quality of each of 63th to 64th practicalexamples is satisfactory. That is, in each of the 63th to 64th practicalexamples, an Mg concentration at the plate thickness center thereof isfrom 0% or more to 0.1% or less by mass. Hence, it is realized that whena core material layer of the tube is joined to a brazing material memberof the fin, an Mg concentration of the tube at a plate thickness centerthereof desirably is from 0% or more to 0.1% or less by mass.

Now, a result of measurement and evaluation of each of 71th to 73thpractical examples and a 71th comparative example is described withreference to an applicable table. That is, the applicant also hasevaluated a corrosion resistance of each of testing samples of the 71thto 73th practical examples and a 71th comparative example as shown in15th table. Here, the 71th to 73th practical examples collectivelycorrespond to the seventh embodiment of the present disclosure. Hereinbelow, a configuration of each of the testing samples and a method ofevaluating a corrosion resistance of the testing samples are described.

First, each of testing samples is configured as described below. As thetesting samples, plate members each functioning as a flow channelforming member are prepared. A thickness of each of prepared tubes is0.2 mm. This tube includes a core material layer, a brazing materialstacked on one side of the core material layer and a cladding layerstacked on the other side of the core material layer opposite to thebrazing material layer. The core material layer is composed of anAl—Mn-based alloy. The brazing material layer is composed of anAl—Si—Bi-based alloy. The cladding layer is composed of an Al—Zn-basedalloy again. Further, zinc (i.e., Zn) is added to the cladding layer ofeach of testing samples to enable a potential difference in a platethickness direction of each of the testing samples to be a value asshown in 15th table. Here, Mg is added to the core material layer.

A corrosion resistance test and a method of evaluating a corrosionresistance are conducted as described below. That is, a corrosion testis applied to each of testing samples. As corrosion resistance tests, inaddition to a CASS test serving as an external corrosion resistancetest, an internal corrosion resistance test is conducted using acorrosive liquid, such as so-called OY water, etc. Specifically, apresence of perforation in each of the testing samples due to corrosionis investigated and a corrosion resistance is thereby evaluated basedthereon as shown in the 15th table. In the table, a sign x indicatespresence of perforation due to corrosion and is defective. In the table,a sign AA indicates absence of perforation and the corrosion resistanceis, therefore, satisfactory. Also, in the table, a sign AAA indicatesthat a degree of corrosion is smaller than a situation indicated by thesign AA and the corrosion resistance is excellent. Here, in the tablethe signs AA and AAA are results of both of the external corrosion andinternal corrosion resistance tests.

A fifteenth table is herein below described.

FIFTEENTH TABLE Potential Corrosion difference resistance Comparative 20X example 71 Practical 50 AA example 71 Practical 100 AAA example 72Practical 200 AAA example 73

As shown in the 15th table, a corrosion resistance of a 71th comparativeexample is defective. By contrast, a corrosion resistance of each of71th to 73th practical examples is satisfactory. That is, in each of the71th to 73th practical examples, a potential difference in the platethickness direction is from 50 mV or more to 200 mV or less. Hence,since the difference is 50 mV or more, a fine corrosion resistance canbe obtained.

Numerous additional modifications and variations of the presentdisclosure are possible in light of the above teachings. It is thereforeto be understood that within the scope of the appended claims, thepresent disclosure may be executed otherwise than as specificallydescribed herein. For example, the heat exchanger is not limited to theabove-described various embodiments and may be altered as appropriate.Similarly, the method of manufacturing the heat exchanger is not limitedto the above-described various embodiments and may be altered asappropriate.

What is claimed is:
 1. An aluminum alloy heat exchanger produced byexcluding flux, the heat exchanger comprising: a flow channel formingmember to form a flow channel which a fluid flows through; a heattransfer member having a heat transfer surface, the heat transfer memberjoined to a flow channel forming surface of the flow channel formingmember, the heat transfer surface wider than the flow channel formingsurface; a tank member joined to the flow channel forming member to forma tank space communicating with the flow channel of the flow channelforming member; a joining member joined to the tank member; a firstfillet formed in a first braze joining portion, in which the heattransfer member and the flow channel forming member join with eachother; a second fillet formed in a second braze joining portion, inwhich the flow channel forming member and the tank member join with eachother; and a third fillet formed in a third braze joining portion inwhich the tank member and the joining member join with each other,wherein the flow channel forming member, the heat transfer member, thetank member and the joining member are composed of aluminum alloys,respectively, wherein an average plate thickness of the flow channelforming member is from 0.100 mm or more to 0.400 mm or less, an averageplate thickness of the heat transfer member is from 0.025 mm or more to0.150 mm or less, an average plate thickness of the tank member is from0.500 mm or more to 2.000 mm or less, and an average plate thickness ofthe joining member is from 0.500 mm or more to 2.000 mm or less, whereineach of the first to third fillets is composed of an aluminum alloycontaining magnesium, bismuth, and silicon, wherein a concentration ofthe magnesium of each of the fillets is from 0.2% or more to 2.0% orless by mass, wherein at least one of the flow channel forming memberand the heat transfer member includes a brazing material layer on asurface thereof, wherein when the flow channel forming member includesthe brazing material layer, a concentration of the magnesium of the flowchannel forming member at its plate thickness center is from 0.1% ormore to 1.0% or less by mass, and when the heat transfer member includesthe brazing material layer, a concentration of the magnesium of the heattransfer member at its plate thickness center is from 0.2% or more to1.0% or less by mass.
 2. An aluminum alloy heat exchanger produced byexcluding flux, the heat exchanger comprising: a flow channel formingmember to form a flow channel in which a fluid flows through; a heattransfer member having a heat transfer surface, the heat transfer memberjoined to a flow channel forming surface of the flow channel formingmember, the heat transfer surface wider than the flow channel formingsurface; a reinforcing member joined to the flow channel forming memberto reinforce the flow channel forming member; a joining member joined tothe reinforcing member; a first fillet formed in a first braze joiningportion in which the heat transfer member and the flow channel formingmember join with each other; a second fillet formed in a second brazejoining portion in which the flow channel forming member and the tankmember join with each other; and a third fillet formed in a third brazejoining portion in which the reinforcing member and the joining memberjoin with each other, wherein the flow channel forming member, the heattransfer member, the reinforcing member and the joining member arecomposed of aluminum alloys, respectively, wherein an average platethickness of the flow channel forming member is from 0.200 mm or more to0.600 mm or less, an average plate thickness of the heat transfer memberis from 0.025 mm or more to 0.150 mm or less, an average plate thicknessof the reinforcing member is from 0.600 mm or more to 2.000 mm or less,and an average plate thickness of the joining member is from 0.600 mm ormore to 2.000 mm or less, wherein each of the first to third fillets iscomposed of an aluminum alloy containing magnesium, bismuth, andsilicon, a concentration of the magnesium of each of the first to thirdfillets ranging from 0.2% or more to 2.0% or less by mass, wherein atleast one of the flow channel forming member and the heat transfermember includes a brazing material layer on a surface thereof, whereinwhen the flow channel forming member includes the brazing materiallayer, a concentration of the magnesium of the flow channel formingmember at its plate thickness center is from 0.1% or more to 1.0% orless by mass, and when the heat transfer member includes the brazingmaterial layer, a concentration of the magnesium of the heat transfermember at its plate thickness center is from 0.2% or more to 1.0% orless by mass.
 3. The aluminum alloy heat exchanger as claimed in claim1, wherein a concentration of the magnesium of each of the fillets is0.3% or more by mass.
 4. The aluminum alloy heat exchanger as claimed inclaim 1, wherein the flow channel forming member includes: a corematerial layer; a brazing material layer located on one side of the corematerial layer; and a cladding layer located on an opposite side to theone side of the core material layer, the cladding layer excludingbrazing material, wherein a part of the brazing material layer of theflow channel forming member is joined to a part of the cladding layer ofthe flow channel forming member, wherein a concentration of themagnesium in a surface layer of the cladding layer is lower than aconcentration of the magnesium of the flow channel forming member at aplate thickness center thereof.
 5. The aluminum alloy heat exchanger asclaimed in claim 1, wherein the flow channel forming member includes: acore material layer; and a cladding layer located on one side of thecore material layer, the cladding layer excluding brazing material,wherein the heat transfer member includes a brazing material layer,wherein the cladding layer is joined to the brazing material layer,wherein a concentration of the magnesium in a surface layer of thecladding layer is lower than the concentration of the magnesium of theflow channel forming member at the plate thickness center thereof. 6.The aluminum alloy heat exchanger as claimed in claim 1, wherein theflow channel forming member includes: a core material layer; and acladding layer located on one side of the core material layer, thecladding layer excluding brazing material, wherein the heal transfermember includes a brazing material layer, wherein the cladding layer isjoined to the brazing material layer, wherein the concentration of themagnesium in the surface layer of the cladding layer is from 0% or moreto 0.1% or less by mass.
 7. The aluminum alloy heat exchanger as claimedin claim 1, wherein one of the flow channel forming member and the heattransfer member includes a core material layer and the brazing materiallayer, wherein the other one of the flow channel forming member and theheat transfer member includes a bare member, a core member of the baremember being exposed, wherein the brazing material layer and the baremember are joined together, wherein a concentration of the magnesium ofthe other one of the flow channel forming member and the heat transfermember at its plate thickness center is from 0% or more to 0.1% or lessby mass.
 8. The aluminum alloy heat exchanger as claimed in claim 1,wherein zinc is added to a surface of the flow channel forming member,wherein a potential difference of 50 mV or more is created in the flowchannel forming member in the thickness direction of the flow channelforming member.
 9. A method of manufacturing the heat exchanger asclaimed in claim 1, the method comprising the steps of: assemblingcomponents into the heat exchanger; placing an assembly of the heatexchanger in an oxygen concentration ambience lower than the atmosphereat either atmospheric pressure or a pressure higher than atmosphericpressure; and brazing components of the heat exchanger without coatingflux thereon.